王光余,靳刚,李占杰,谭辉,詹奇云,林怀鑫,王晓然.基于表面粗糙度和反射率多目标优化的6061铝合金超精密车削工艺研究[J].表面技术,2024,53(12):193-206.
WANG Guangyu,JIN Gang,LI Zhanjie,TAN Hui,ZHAN Qiyun,LIN Huaixin,WANG Xiaoran.Ultra-precision Turning Process of 6061 Aluminum Alloy Based on Multi-objective Optimization of Surface Roughness and Reflectivity[J].Surface Technology,2024,53(12):193-206 |
| 基于表面粗糙度和反射率多目标优化的6061铝合金超精密车削工艺研究 |
| Ultra-precision Turning Process of 6061 Aluminum Alloy Based on Multi-objective Optimization of Surface Roughness and Reflectivity |
| 投稿时间：2023-08-20 修订日期：2023-11-16 |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.12.016 |
| 中文关键词: 单点金刚石车削 6061铝合金 正交试验 表面粗糙度 表面光学反射率 灰色关联分析 |
| 英文关键词:single-point diamond turning 6061 aluminum alloy orthogonal test surface roughness surface optical reflectivity grey correlation analysis |
| 基金项目:国家自然科学基金面上项目(51875487);天津市自然科学基金重点项目(22JCZDJC00740) |
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| Author | Institution |
| WANG Guangyu | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| JIN Gang | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| LI Zhanjie | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| TAN Hui | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| ZHAN Qiyun | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| LIN Huaixin | School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin 300222, China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin 300222, China |
| WANG Xiaoran | Tianjin Aerospace Institute of Electrical and Mechanical Equipment, Tianjin 300301, China |
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| 中文摘要: |
| 目的 探究工艺参数对6061铝合金滚压件超精密车削性能的影响，对工件超精密车削加工表面粗糙度和表面光学反射率进行协同优化研究。方法 首先，对6061铝合金材料表面进行单向超声振动滚压以提高工件表面质量。其次，设计了四因素四水平的超精密车削正交试验，研究了切削工艺参数(主轴转速、进给速度、背吃刀量、刀尖半径)对6061铝合金滚压件表面粗糙度及表面光学反射率的影响规律。最后，采用灰色关联分析方法，将多个工艺目标参数优化问题转化为单目标的灰色关联度优化问题，通过超精密车削试验对优化结果进行验证。结果 主轴转速对表面粗糙度Ra和Sa的影响最显著，其次是刀尖半径和背吃刀量，进给速度的影响最小;工艺参数对可见光波段和中红外光波段反射率的影响程度与表面粗糙度一致，各参数按对近红外光波段反射率影响程度由大到小的顺序依次为背吃刀量、刀尖半径、进给速度、主轴转速;通过灰色关联分析获得优化工艺参数组合为主轴转速3 000 r/min、进给速度10 mm/min、背吃刀量5 μm、刀尖半径0.5 mm，此时对应的表面粗糙度Ra和Sa分别为2.162 nm和7.855 nm，可见光、近红外光、中红外光波段反射率分别为88.892%、88.893%、97.788%。结论 通过优化结果能够有效降低表面粗糙度、提升表面光学反射率，对制造高水平金属反射镜具有十分重要的现实意义和研究价值。 |
| 英文摘要: |
| Single point diamond turning (SPDT) is currently an important technology in the field of ultra-precision machining, mostly used in the manufacture of high-precision optical components. The 6061 aluminum alloy combined with SPDT technology, can be directly used for the optical system to create a high level of metal mirrors. Since the surface machining accuracy and surface optical properties in single-point diamond ultra-precision turning technology are affected by many factors, it is necessary to analyze the effect of process parameters on the surface roughness and optical properties of the material after ultra-precision turning. The work aims to explore the effect of process parameters on the ultra-precision turning performance of rolled 6061 aluminum alloy parts, and carry out a synergistic optimization study on the surface roughness and surface optical reflectivity of the workpiece ultra-precision turning process. First of all, the surface of 6061 aluminum alloy material was subject to one-way ultrasonic vibration rolling to improve the surface quality of the workpiece. The surface of the material was subject to the joint effect of the spindle speed of the rolling head, feed speed and high-frequency ultrasonic impact amplitude, and the preparation of test pieces by ultrasonic rolling before ultra-precision turning laid a good foundation for the subsequent ultra-precision turning test. Then, a 4-factor, 4-level orthogonal test of ultra-precision turning was designed to investigate the effect of cutting process parameters (spindle speed, feed rate, back-eating amount, and tip radius) on the surface roughness and surface optical reflectivity of rolled 6061 aluminum alloy parts. In addition, the interconnection between surface roughness and surface reflectivity was explored. Finally, the grey correlation analysis method was adopted to transform multiple process objective parameter optimization problems into single-objective grey correlation degree optimization problems, and the optimization results were verified through the ultra-precision turning test. By comparing the surface roughness Sa and the visible VIS reflectance trend, it could be seen that the roughness value and the surface reflectance had a negative correlation, i.e., an increase in surface roughness corresponding to a decrease in the surface reflectivity of the material. However, this negative correlation was not obvious when the trends of surface roughness Ra and VIS reflectivity were compared. The spindle speed had the most significant effect on the surface roughness Ra and Sa, followed by the tool tip radius and the amount of back draft, and the feed speed had the least effect. The degree of effect of process parameters on the reflectivity of the visible and mid-infrared bands was the same as that of the surface roughness, and the degree of effect on the reflectivity of the near-infrared bands was as follows:the amount of back draft > the tool tip radius > the feed speed > the spindle speed. The optimized process parameters were obtained through the grey correlation analysis. The optimized process parameters were spindle speed of 3 000 r/min, feed speed of 10 mm/min, back draft of 5 μm, and tip radius of 0.5 mm, at which the corresponding surface roughness Ra and Sa were 2.162 nm and 7.855 nm, and the reflectivity of visible, near-infrared, and mid-infrared wavelengths were 88.892%, 88.893%, and 97.788%, respectively. The optimization results can effectively reduce the surface roughness and improve the surface optical reflectivity, which is of great practical significance and research value for manufacturing high-level metal mirrors. |
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