金刚石与磨料磨具工程2025，Vol.45Issue(6)：727-739,13.DOI:10.13394/j.cnki.jgszz.2024.0040
聚晶金刚石断刀具屑槽的皮秒激光铣削工艺优化
Optimization of picosecond laser milling process for polycrystalline diamond tool chip-breaking grooves
摘要
Abstract
Objectives:The reliability of continuous processing is an important guarantee for large-scale production and automated manufacturing systems.Polycrystalline diamond(PCD)cutting tools produce elongated chips during the cutting of plastic metals,which directly affect the surface quality,machining accuracy,tool life,as well as the vibration and performance of the machine tool.The most common method to avoid the formation of elongated chips is to design a chip-breaking groove on the front cutting surface of the tool to forcibly break the chips.Laser processing has the charac-teristics of non-contact processing,high flexibility,high precision,and no material selectivity,and is suitable for the processing of PCD tool chip grooves.Reliable processing parameters are a necessary condition for efficient and high-quality automated processing of PCD chip grooves.The response surface method based on orthogonal experimental design is a commonly used method for optimizing process parameters and establishing a mathematical model for pre-dicting process quality.Through this method,the infrared picosecond laser milling process parameters suitable for PCD tool chip groove manufacturing are obtained,and the genetic algorithms are used to screen them,thereby producing three typical PCD chip-breaking groove structures.Methods:The response surface method is adopted to optimize the design of infrared picosecond laser milling process parameters suitable for the manufacturing of chip-breaking grooves of PCD tools,and a prediction model for processing quality and efficiency indicators is established.Taking process parameters such as single-pulse energy density,pulse overlap rate and scan overlap rate as factors,the numerical levels of the factors are determined through single-factor experiments.Then,taking the ablation depth,the material removal rate and the surface roughness as the objective functions,based on the Box-Behnken response surface method,the influ-ence degree of each process parameter on the objective function is obtained through variance analysis and statistical ana-lysis,and a numerical model for the prediction of the objective function is established.Finally,the genetic algorithm is adopted to screen the optimal process parameters.Results:(1)The prediction models for ablation depth,material re-moval rate and surface roughness obtained based on the Box-Behnken response surface method have good accuracy and reliability,and can actually predict the quality and efficiency of infrared picosecond laser milling in the chip-breaking groove of PCD.(2)Single-pulse energy density is the main factor affecting ablation depth,material removal rate and surface roughness,followed by scanning overlap rate and pulse overlap rate.The higher the single-pulse energy density,the greater the ablation depth,material removal rate,and surface roughness.The material removal rate decreases with the increase of the scanning overlap rate,but is not sensitive to the pulse overlap rate.The sensitivity of surface rough-ness to pulse overlap rate is also relatively low.Under the condition of constant single-pulse energy density,reducing both the scanning overlap rate and the pulse overlap rate simultaneously will lower the surface roughness.(3)Within the scope of this study,selecting a single-pulse energy density of 4.7-5.4 J/cm2,a pulse overlap rate of 88%-90%and a scan overlap rate of 91%-93%,the efficient,high-precision and high-quality machining of PCD tool chip-breaking grooves can be achieved with a surface roughness of less than 0.200 μm.Conclusions:The infrared picosecond laser milling process of the PCD chip-breaking grooves is mainly studied,and the process parameters are optimized by using the Box-Behnken response surface method.Subsequently,the NSGA-II genetic algorithm is adopted to screen the appropriate process parameters,and the good consistency between experimental values and model prediction results proves that the numerical model obtained based on the response surface method can well predict the ablation depth,material removal rate,and surface roughness under different process parameters.The efficient,high-precision and high-quality machin-ing of PCD turning tool chip-breaking grooves can be achieved with a surface roughness of less than 0.200 μm.关键词
聚晶金刚石/车刀断屑槽/皮秒激光铣削/工艺参数优化/响应面法Key words
polycrystalline diamond(PCD)/chip-breaking groove of turning tool/picosecond laser milling/pro-cessing parameters optimization/response surface method分类
矿业与冶金引用本文复制引用
胡小月,丁峰,郭靖雅,洪云,王成勇..聚晶金刚石断刀具屑槽的皮秒激光铣削工艺优化[J].金刚石与磨料磨具工程,2025,45(6):727-739,13.基金项目
广东省重点领域研发计划项目(2020B090924005). （2020B090924005）
