摘要
碳纤维增强树脂基复合材料(Carbon fiber reinforced plastic,CFRP)具有高比强度、高比模量、可设计性强、耐腐蚀耐疲劳等优良特性,在航空航天、交通运输、风电能源及医疗等领域广泛应用.然而,其各向异性、非均质性、层间强度低和温度敏感性增加了加工难度,传统机械加工方法存在刀具磨损严重、加工表面质量及尺寸精度难以控制等问题,易产生分层、毛刺、纤维脱粘和表面空洞等加工缺陷,严重降低碳纤维增强树脂基复合材料构件的服役性能和可靠性.针对上述挑战,特种加工技术逐步受到研究和应用.针对激光束加工、电火花加工、水射流加工和超声振动加工四个最为广泛应用的特种加工技术展开综述,详细介绍各个特种加工技术的优势与存在的挑战,对缺陷形成机理进行分析,并总结缺陷抑制方法,最后归纳各特种加工技术的适用场景并得出结论展望未来研究.综述表明:与传统机械加工相比,特种加工在微细结构、高精度、复杂形状工件加工方面展现出独特优势;但是其材料去除率显著低于传统机械加工,因此在大批量加工中仍难以完全替代传统机械加工.未来研究应着重探索特种加工工艺优化、特种与传统加工的复合工艺、专用化与智能化装备开发等方面,同时关注电子束、离子束等其他特种加工工艺的潜力.特种加工技术将对提升先进复合材料加工的精度与效率有着重要意义,将推动高性能材料朝着更广泛的应用场景迈进.
Abstract
Carbon fiber reinforced plastic(CFRP)composites exhibit excellent properties such as high specific strength,high specific modulus,good design flexibility and corrosion/fatigue resistance,which endows them with wide applications in aerospace,transportation,wind power and biomedical.However,their anisotropy,non-homogeneity,low interlaminar strength and thermal-sensitive nature pose challenges in its machining.Conventional machining methods encounter problems such as severe tool wear,difficulty in controlling machining surface quality and accuracy,and the tendency to produce delamination,burrs,fiber debonding,and surface cavity.These defects significantly reduce the service performance and reliability of CFRP components.To address these challenges,non-conventional machining methods have been developed and deployed.This paper presents a comprehensive review of four widely applied special machining techniques for CFRP:laser beam machining,electrical discharge machining,waterjet machining and ultrasonic vibration machining.The advantages and challenges associated with each technique are detailed,and the mechanisms of defect formation are analyzed,along with defect suppression methods.The review concludes by summarizing the suitable application scenarios for each special machining technique and offers insights into future research directions.Literature review suggests that non-conventional machining shows unique advantages in manufacturing of intricate microstructures,high-precision features and complex shapes.However,its material removal rate is significantly lower than that of traditional machining,limiting its feasibility for large-scale production.Future research should prioritize optimizing non-conventional machining process,hybrid machining process that integrate conventional and non-conventional machining,and development of advanced specialized and intelligent equipment.Additionally,the potential of other non-conventional machining techniques,such as electron beam and ion beam machining,should be actively explored.These studies are crucial for improving the precision and efficiency of advanced composite machining,fostering broader applications of high-performance material.
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