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Design and manufacture of a carbon fiber epoxy rotating boring bar

机译：碳纤维环氧旋转镗杆的设计与制造

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摘要

High speed boring operations of deep holes with steel or tungsten boring bars are often hindered by the chatter vibration of boring bars because of their low dynamic stiffness and natural frequencies. The chatter is a self-excited vibration that occurs in metal cutting if, either the chip width is too large with respect to the dynamic stiffness of the system, which is proportional to the damping and static stiffness of the boring bar, or the rotating speed of the boring bar approaches one of its natural frequencies, which is proportional to the specific stiffness (E/ρg) of the material used. In this study, a rotating boring bar was designed and manufactured with high stiffness pitch-based carbon fiber epoxy composite to meet the requirements of boring at high rotating speed because carbon fiber epoxy composite materials have a much higher specific stiffness and higher damping than conventional boring bar materials. The optimum design parameters for the composite boring bar were experimentally determined with respect to material types and dimensions of the boring bar through vibration tests. The dynamic characteristics of the composite boring bar developed were measured by the boring operation of aluminum engine blocks. From experiments, it was found that the dynamic stiffness of the composite boring bar was about 30% higher than that of the tungsten carbide boring bar. Also, chatter did not occur up to the ratio of length to diameter (l/d) of 10.7, which is about a 30% improvement compared to the tungsten boring bar of l/d of 8.0.
机译：钢或钨钢镗杆的深孔高速镗削操作通常由于其低的动态刚度和固有频率而受到镗杆颤振的阻碍。如果切屑宽度相对于系统的动态刚度过大（与镗杆的阻尼和静态刚度成正比），或者在旋转速度上成比例，则颤振是在金属切削中发生的自激振动。镗杆的“固有频率”接近其固有频率之一，该固有频率与所用材料的比刚度（E /ρg）成比例。在这项研究中，使用高刚度沥青基碳纤维环氧复合材料设计和制造旋转镗杆，以满足高转速下的镗孔要求，因为碳纤维环氧复合材料比常规镗孔具有更高的比刚度和更高的阻尼酒吧材料。通过振动测试，通过实验确定了复合镗杆的最佳设计参数，涉及材料和镗杆的尺寸。通过铝制发动机缸体的镗削操作来测量开发的复合镗杆的动力特性。从实验中发现，复合镗杆的动态刚度比碳化钨镗杆的动态刚度高约30％。而且，直到长度与直径之比（l / d）为10.7时，都不会发生颤动，与钨/ l / d 8.0的镗孔杆相比，这大约提高了30％。

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