| ZHANG Peirong,ZHANG Xia,HU Shunrui,SU Guosheng,DU Jin,XIA Yan,LIU Zhanqiang.Effect of Interfacial Structure on the Milling Stability of Heterogeneous Cladding Layer on Thin-walled Parts[J],54(11):159-172 |
| Effect of Interfacial Structure on the Milling Stability of Heterogeneous Cladding Layer on Thin-walled Parts |
| Received:November 15, 2024 Revised:February 13, 2025 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.11.013 |
| KeyWord:laser cladding interfacial structure stress-strain milling stability surface quality |
| Author | Institution |
| ZHANG Peirong |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| ZHANG Xia |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| HU Shunrui |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| SU Guosheng |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| DU Jin |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| XIA Yan |
School of Mechanical Engineering,Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology Shandong Academy of Sciences, Jinan , China;Shandong Institute of Mechanical Design and Research, Jinan , China |
| LIU Zhanqiang |
School of Mechanical Engineering, Shandong University, Jinan , China |
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| Abstract: |
| In recent years, laser cladding has gradually expanded into the manufacturing and repair of complex and weakly rigid structural components. However, the heterogeneous interface between the cladding layer and the substrate can lead to machining vibrations when the laser cladding is used for surface repair of thin-walled parts, becoming a bottleneck in repairing of thin-walled parts by laser cladding method. The work aims to study the effect of interfacial structures on the stress-strain evolution through finite element simulation and the milling stability of heterogeneous cladding layer on the surface of thin-walled parts based on a single factor experiment, and further optimize the interfacial structure parameters by Taguchi experimental design. The milling stability under different interfacial structures and parameters is evaluated through modal analysis, cutting vibration and surface roughness testing. In addition, the milling stability domain of the laser cladded workpiece with straight and optimized interface structures is evaluated by stability lobe diagrams. The results indicate that the introduction of longitudinal interfaces due to the interfacial structures reduces the stress energy dissipation passing through the interface, thus decreasing the interfacial stress difference. The natural frequency and stiffness of the cladding layer workpiece show an opposite trend of change with the increasing interfacial structures. On the one hand, the reduction of stiffness is the greatest when a rectangular interface is set, followed by isosceles trapezoids, semicircles, and triangles. The stiffness decreases first and then increases with the increase of shape factor, decreases with the increase of interfacial depth, and increases with the increase of interfacial spacing. On the other hand, the first-order natural frequency of the workpiece with the rectangular interface is the highest, followed by isosceles trapezoidal, triangular, and semicircle structures. The natural frequency increases with the increase of shape factor when the interfacial depth is small, and decreases with the increase of shape factor when the interfacial depth is large. Meanwhile, the natural frequency increases with the increase of interfacial depth and decreases with the increase of interfacial spacing. The milling vibration acceleration decreases by 32% and the milled surface roughness also decreases by 23.9% when a triangular interface is used instead of a straight interface. As a result, the cutting vibration and surface roughness during cutting can be effectively reduced with the increasing interface structures. The improvement effects on cutting vibration and surface roughness are in descending order as follows:triangle, rectangle, isosceles trapezoid, and semicircle. The milled surface roughness decreases by 23.9% when the triangular interface is increased compared to the straight interface. In detail, the shape factor of the interfacial structure has the greatest impact on the vibration acceleration and surface roughness of the workpiece, followed by the interfacial depth, and the interfacial spacing has the smallest impact. When the shape factor is smaller, the interfacial depth is larger, and the interfacial spacing is smaller, the vibration acceleration of the workpiece will be smaller, and the stability of the workpiece will be stronger, and further the surface roughness of the workpiece after milling will be reduced. The optimized interfacial structure has a shape factor of 0.06, interfacial depth of 3 mm, and spacing of 0 mm. The milling stability lobe diagram shows that the stability domain of the optimized interfacial structure workpiece has increased by 117% when a linear interface is compared to a straight interface. The results confirm that pre-processing the interfacial structure on the substrate can improve the milling stability of the heterogeneous cladding layer on the surface of thin-walled parts to a certain extent, thereby improving the machining quality. |
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