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Article(id=1241686769415024906, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241686759470329942, articleNumber=null, orderNo=null, doi=10.16579/j.issn.1001.9669.2025.09.010, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1750003200000, receivedDateStr=2025-06-16, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1773970795252, onlineDateStr=2026-03-20, pubDate=1757865600000, pubDateStr=2025-09-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1773970795252, onlineIssueDateStr=2026-03-20, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1773970795252, creator=13701087609, updateTime=1773970795252, updator=13701087609, issue=Issue{id=1241686759470329942, tenantId=1146029695717560320, journalId=1227999626482147330, year='2025', volume='47', issue='9', pageStart='1', pageEnd='249', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1773970792882, creator=13701087609, updateTime=1773970911747, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1241687258093375901, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241686759470329942, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1241687258093375902, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241686759470329942, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=113, endPage=121, ext={EN=ArticleExt(id=1241686769721209110, articleId=1241686769415024906, tenantId=1146029695717560320, journalId=1227999626482147330, language=EN, title=Research on tool wear and surface quality of ultrasonic vibration assisted drilling HR-2 hydrogen resistant steel deep small holes, columnId=null, journalTitle=Journal of Mechanical Strength, columnName=null, runingTitle=null, highlight=null, articleAbstract=

In response to the problems of reduced surface quality and severe twist drill wear in HR-2 hydrogen resistant steel deep small holes drilling, integrated thermal coupling finite element simulation with experimental investigations of deep small holes drilling to analyze the variations in tool wear, drilling temperature, and the quality of the machined surface during the process of machining deep small holes. The improvement effect of introducing ultrasonic vibration on poor surface quality and severe tool drilling wear was analyzed by comparing ultrasonic vibration assisted drilling (UVAD) and conventional drilling (CD). The results show that as the drilling depth increases, the heat accumulation of the tool's transverse and cutting edges significantly increases, gradually leading to problems such as coating peeling, edge passivation and chipping.Concurrently, the accumulation of cutting heat on the surface of the machined hole causes temperature rise, resulting in material coating, debris adhesion, oblique scratching and other problems on the machined surface, resulting in a deterioration of surface quality and an elevation in surface roughness. Compared to CD, the UVAD effectively reduces drilling temperature,helps to reduce tool wear and maintain cutting edge integrity, while suppressing the increase in surface roughness during machining, ultimately improving surface quality.

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DONG Zhigang, E-mail：
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针对HR-2抗氢钢深小孔钻削加工中表面质量降低、麻花钻磨损严重的问题，通过热力耦合有限元仿真与深小孔钻削试验相结合的方法，研究深小孔加工中刀具磨损、钻削温度和加工表面质量的变化趋势，对比超声振动辅助钻削（Ultrasonic Vibration Assisted Drilling，UVAD）和常规钻削（Conventional Drilling，CD）2种加工方式，分析超声振动对表面质量差、刀具磨损严重等问题的改善作用。结果表明，随着钻削深度增大，刀具横刃和切削刃热量积累显著增大，逐渐发生涂层剥落、刃口钝化、崩刃等问题，同时，加工孔表面切削热累积导致温度升高，加工表面出现材料涂抹、碎屑黏附、斜向划擦等问题，使表面质量下降和表面粗糙度增大。UVAD相较于CD，有效降低了钻削温度，有助于减少刀具磨损，保持切削刃的完整性，同时降低了加工表面粗糙度，最终提高了加工表面质量。

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董志刚，男，1980年生，内蒙古赤峰人，博士，教授，博士研究生导师；主要研究方向为硬脆材料精密、超精密加工、多机器人融合智能制造、集成电路基片超精密加工；E-mail：。
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蒋凯宁，男，2001年生，浙江宁波人，在读硕士研究生；主要研究方向为高性能精密、超精密加工；E-mail：。

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蒋凯宁，男，2001年生，浙江宁波人，在读硕士研究生；主要研究方向为高性能精密、超精密加工；E-mail：。

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蒋凯宁，男，2001年生，浙江宁波人，在读硕士研究生；主要研究方向为高性能精密、超精密加工；E-mail：。

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figureFileSmall=lbz4f3iXKDdryYl1plRSNw==, figureFileBig=Y9DnPwSg/E4lwYYu3L6cjQ==, tableContent=null), ArticleFig(id=1241810805549761520, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241686769415024906, language=EN, label=Tab.1, caption=

Basic mechanical parameters of materials

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参数Parameter硬质合金
Cemented carbide		HR-2钢
HR-2 steel
密度Density/（g/cm3）147.85
弹性模量Elastic modulus/GPa640206
泊松比Poisson ratio0.220.3
热传导率
Thermal conductivity/[W/（m·K）]		7520
热膨胀系数
Coefficient of thermal expansion/℃-1		5×10-61.1×10-5
比热容
Specific heat capacity/[J/（kg·K）]		300465
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材料基本力学参数

, figureFileSmall=null, figureFileBig=null, tableContent=
参数Parameter硬质合金
Cemented carbide		HR-2钢
HR-2 steel
密度Density/（g/cm3）147.85
弹性模量Elastic modulus/GPa640206
泊松比Poisson ratio0.220.3
热传导率
Thermal conductivity/[W/（m·K）]		7520
热膨胀系数
Coefficient of thermal expansion/℃-1		5×10-61.1×10-5
比热容
Specific heat capacity/[J/（kg·K）]		300465
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J-C constitutive parameters of HR-2 hydrogen resistant steel

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参数ParameterA/MPaB/MPanCm
值Value5536010.2340.020.8
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HR-2抗氢钢J-C本构参数

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参数ParameterA/MPaB/MPanCm
值Value5536010.2340.020.8
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J-C damage parameters of HR-2 hydrogen resistant steel

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参数ParameterD1D2D3D4D5
值Value0.063.30-1.960.001 80.58
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HR-2抗氢钢J-C损伤参数

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参数ParameterD1D2D3D4D5
值Value0.063.30-1.960.001 80.58
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超声振动辅助钻削HR-2抗氢钢深小孔刀具磨损与表面质量研究
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蒋凯宁 1 , 王佳勋 2 , 张园 2 , 徐飞飞 2 , 刘文浩 1 , 董志刚 1
机械强度 | 2025,47(9): 113-121
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机械强度 | 2025, 47(9): 113-121
超声振动辅助钻削HR-2抗氢钢深小孔刀具磨损与表面质量研究
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蒋凯宁1 , 王佳勋2, 张园2, 徐飞飞2, 刘文浩1, 董志刚1
作者信息
  • 1.大连理工大学 高性能精密制造全国重点实验室，大连　116024
  • 2.中国工程物理研究院 机械制造工艺研究所，绵阳　621900

    • 蒋凯宁，男，2001年生，浙江宁波人，在读硕士研究生；主要研究方向为高性能精密、超精密加工；E-mail：。

通讯作者:

董志刚，男，1980年生，内蒙古赤峰人，博士，教授，博士研究生导师；主要研究方向为硬脆材料精密、超精密加工、多机器人融合智能制造、集成电路基片超精密加工；E-mail：。
Research on tool wear and surface quality of ultrasonic vibration assisted drilling HR-2 hydrogen resistant steel deep small holes
Kaining JIANG1 , Jiaxun WANG2, Yuan ZHANG2, Feifei XU2, Wenhao LIU1, Zhigang DONG1
Affiliations
  • 1.State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian 116024, China
  • 2.Institute of Mechanical Manufacturing Technology, China Academy of Engineering Physics, Mianyang 621900, China
出版时间: 2025-09-15 doi: 10.16579/j.issn.1001.9669.2025.09.010
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摘要
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针对HR-2抗氢钢深小孔钻削加工中表面质量降低、麻花钻磨损严重的问题，通过热力耦合有限元仿真与深小孔钻削试验相结合的方法，研究深小孔加工中刀具磨损、钻削温度和加工表面质量的变化趋势，对比超声振动辅助钻削（Ultrasonic Vibration Assisted Drilling，UVAD）和常规钻削（Conventional Drilling，CD）2种加工方式，分析超声振动对表面质量差、刀具磨损严重等问题的改善作用。结果表明，随着钻削深度增大，刀具横刃和切削刃热量积累显著增大，逐渐发生涂层剥落、刃口钝化、崩刃等问题，同时，加工孔表面切削热累积导致温度升高，加工表面出现材料涂抹、碎屑黏附、斜向划擦等问题，使表面质量下降和表面粗糙度增大。UVAD相较于CD，有效降低了钻削温度，有助于减少刀具磨损，保持切削刃的完整性，同时降低了加工表面粗糙度，最终提高了加工表面质量。

抗氢钢  /  深小孔  /  超声振动辅助钻削  /  有限元仿真  /  刀具磨损  /  表面质量

In response to the problems of reduced surface quality and severe twist drill wear in HR-2 hydrogen resistant steel deep small holes drilling, integrated thermal coupling finite element simulation with experimental investigations of deep small holes drilling to analyze the variations in tool wear, drilling temperature, and the quality of the machined surface during the process of machining deep small holes. The improvement effect of introducing ultrasonic vibration on poor surface quality and severe tool drilling wear was analyzed by comparing ultrasonic vibration assisted drilling (UVAD) and conventional drilling (CD). The results show that as the drilling depth increases, the heat accumulation of the tool's transverse and cutting edges significantly increases, gradually leading to problems such as coating peeling, edge passivation and chipping.Concurrently, the accumulation of cutting heat on the surface of the machined hole causes temperature rise, resulting in material coating, debris adhesion, oblique scratching and other problems on the machined surface, resulting in a deterioration of surface quality and an elevation in surface roughness. Compared to CD, the UVAD effectively reduces drilling temperature,helps to reduce tool wear and maintain cutting edge integrity, while suppressing the increase in surface roughness during machining, ultimately improving surface quality.

Hydrogen resistant steel  /  Deep small holes  /  Ultrasonic vibration assisted drilling  /  Finite element simulation  /  Tool wear  /  Surface quality
蒋凯宁, 王佳勋, 张园, 徐飞飞, 刘文浩, 董志刚. 超声振动辅助钻削HR-2抗氢钢深小孔刀具磨损与表面质量研究. 机械强度, 2025 , 47 (9) : 113 -121 . DOI: 10.16579/j.issn.1001.9669.2025.09.010
Kaining JIANG, Jiaxun WANG, Yuan ZHANG, Feifei XU, Wenhao LIU, Zhigang DONG. Research on tool wear and surface quality of ultrasonic vibration assisted drilling HR-2 hydrogen resistant steel deep small holes[J]. Journal of Mechanical Strength, 2025 , 47 (9) : 113 -121 . DOI: 10.16579/j.issn.1001.9669.2025.09.010
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0　引言
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HR-2抗氢钢作为新一代高性能特种合金材料，因其具备优异的高强度、抗氢脆性及高温稳定性，在涉氢工业领域展现出显著优势，广泛应用于航空航天、发动机燃料管路等极端工况部件[1]。此类部件常需加工直径小于3 mm、深径比大于10的深小孔，以满足流体传输、冷却通道等功能需求。
近年来，钻削仿真技术取得了显著进展。有限元模型和解析模型是2种主要的仿真方法。有限元模型通过模拟材料变形、热传导和应力分布，能够较准确地预测钻削力、转矩和温度等参数，余芬等[2]利用Abaqus有限元软件建立了碳纤维增强复合材料（Carbon Fiber Reinforced Plastic, CFRP）钻削拉伸仿真模型，探究了刀具转速、钻削进给量和钻头顶角对CFRP层合板钻削后拉伸剩余强度的影响。解析模型则基于力学和热力学原理，通过简化假设推导出钻削力的解析表达式，适用于快速预测和参数优化[3-4]。
研究表明，实际加工过程中刀具磨损主要受切削力、温度和材料特性的影响[5]。WANG等[6]通过试验研究了高耐磨陶瓷微钻加工玻璃纤维增强材料（Glass Fiber Reinforced Plastics, GFRP）时的刀具磨损和磨损机制，发现在动态载荷下，切削刃边缘出现了磨粒磨损和圆钝化，且随着每齿进给量增大，横刃由磨粒磨损逐渐过渡为黏着磨损。HR-2抗氢钢因其高硬度和低热导率，加工过程中易产生严重刀具磨损和表面加工质量低下的情况。在常规材料的深小孔钻削加工中，可以通过加入切削液达到改善表面质量和延长刀具寿命的目的[7-8]，但切削液中的极性分子可能渗入加工表面的微裂纹或晶界，形成氢吸附活性位点，在服役环境中优先吸附环境氢，加速氢原子向材料内部的扩散和富集，最终导致抗氢钢材料抗氢性能的降低和关键零部件氢脆敏感性的提升[9-10]。因此，为保证HR-2抗氢钢的抗氢性能，深小孔钻削过程中应避免使用冷却液。
国内外学者提出在钻削过程中引入超声振动，通过在钻削刀具轴向进给方向上叠加频率大于15 kHz的高频振动，将刀具的高速旋转、轴向进给与高频振动结合成切削运动，从而实现降低钻削力和转矩[11]、延长麻花钻的使用寿命[12]、并提高孔表面的质量的目标[13]。目前超声振动辅助钻削（Ultrasonic Vibration Assisted Drilling, UVAD）技术已广泛应用于难加工材料。隗雨欣等[14]通过开展1J22软磁合金钻削试验发现，超声振动作用可以改善排屑条件从而有效提高晶粒细化、加工硬化等表面完整性指标。LIAO等[15]研究超声振动钻孔镍基高温合金材料时振幅和频率对钻孔性能的影响，结果显示，小超声振幅和高超声振动频率可以有效提高刀具寿命并降低切屑尺寸。王春浩等[16]建立了CFRP/TC4合金叠层的切削刃轴向力模型，分析发现横刃挤压深度改变是纵扭超声振动有效降低轴向力的主要原因，且轴向力与TC4毛刺、CFRP孔壁的损伤程度有关。孙婷等[17]开展了针对Cf/SiC复合材料的常规钻削（Conventional Drilling, CD）和UVAD等不同加工条件的对比试验，结果显示，引入超声振动可以有效抑制孔出口缺陷，施加切削液有利于降温排屑并改善加工质量。闫帆[18]利用有限元仿真软件Abaqus，构建Al基体、SiC颗粒以及Cohesive内聚力模型的本构参数，建立SiCp/Al复合材料的三维切削仿真模型，研究表明，超声辅助加工可以减少切屑堆积、提高加工表面平整度、降低SiC颗粒去除时对基体的损伤。然而，现有研究多集中于常规材料小深径比钻削加工，对HR-2抗氢钢的深小孔钻削加工研究较少，且缺乏在深小孔加工中对刀具磨损动态过程的精确分析。
HR-2抗氢钢深小孔钻削过程中，切屑在狭长孔道内易形成螺旋状堆积，引发排屑不畅甚至刀具断裂[19]。钻削加工区热量积聚显著，局部高温会加剧刀具磨损并导致工件表面加工质量下降[20]。此外，刀具与孔壁持续摩擦导致刃口快速钝化，也将直接影响孔壁粗糙度与尺寸精度[21]。现有研究多聚焦于常规孔加工参数优化，而对深小孔动态钻削过程中热力耦合效应与刀具渐进磨损的关联机制缺乏系统性解析，制约了高精度抗氢钢构件的可靠制造。
因此，本研究旨在建立HR-2抗氢钢深小孔钻削的仿真模型，并通过试验验证模型的准确性，揭示超声振动对刀具磨损及表面质量的影响规律。首先，基于有限元方法构建HR-2抗氢钢深小孔钻削有限元仿真模型，实现UVAD和CD这2种不同加工方式的热力耦合仿真。然后，开展HR-2抗氢钢深小孔UVAD和CD对比试验，研究引入超声振动对刀具磨损、加工表面形貌及粗糙度的影响。
1　试验方法
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1.1　有限元仿真模型构建
利用Abaqus 2025有限元仿真软件模拟HR-2抗氢钢深小孔钻削过程。有限元仿真模型主要由麻花钻刀具和工件2个部件装配而成。麻花钻刀具及工件的几何结构如图1所示，麻花钻顶角为120°，螺旋角为30°，直径为2 mm；工件为圆柱体，直径为3 mm，长度为20 mm。
本文所研究的麻花钻刀具材料为硬质合金，工件材料为HR-2抗氢钢，其基本力学参数如表1所示。
抗氢钢深小孔钻削过程中，材料持续处于高温、高应变、高应变率的状态，Johnson-Cook（J-C）本构关系同时涵盖了塑性应变、变形速率以及热软化效应的作用，适用于Abaqus高速切削仿真。因此本文选用J-C本构模型，即
式中，σ为等效流动应力；第1项为应变硬化项，其中A为初始材料屈服应力；B为材料应变强化常数；ɛ为等效塑性应变；n为应变强化系数；第2项为应变速率项，其中C为应变率强化系数；为等效塑性应变率；为参考等效塑性应变率；第3项为热软化项，其中T为材料变形温度；Tmelt为材料熔化温度；Troom为室温（293 K）；m为热软化系数。HR-2抗氢钢J-C本构参数如表2所示。
J-C损伤是基于累计损伤准则来判断材料是否满足损伤初始条件，当与等效塑性应变累积相关的状态变量等于1时，模型中材料单元积分点达到初始失效准则，单元开始出现损伤。J-C损伤符合金属结构损伤的研究，因此本研究采用J-C损伤模型来定义材料的初始损伤，为
式中，为等效损伤应变，三项分别表示应变、应变率、温度对材料应变的影响；P为静水压力；为von-Mises的等效应力；D1~D5为材料损伤参数。表3列出了HR-2抗氢钢的J-C损伤参数。
对部件进行高质量网格划分可以有效提高仿真计算的精度和效率，图2展示了HR-2抗氢钢深小孔钻削有限元模型的网格划分情况。在钻削仿真过程中，刀具设置为刚体，全局网格尺寸为0.3 mm，部件共有1 013个网格，网格类型为C3D4T；工件设置为变形体，沿径向划分直径为2.2 mm的圆形接触区和直径为2.2~3 mm的环形非接触区，纵向网格尺寸为0.03 mm。工件接触区在刀具的作用下发生材料去除，为提高计算精度需要进行网格细化，沿径向网格尺寸设为0.02~0.04 mm；工件非接触区不直接与刀具发生接触，因此可以适当粗化网格以提高计算效率，则沿径向网格尺寸为0.04~0.2 mm。工件部件轴向均匀网格尺寸为0.03 mm，最终工件接触区网格数量为2 004 660个，非接触区网格数量为229 104个，网格类型为C3D8RT。
实际钻削过程中工件保持固定，麻花钻绕轴线高速旋转的同时不断向下进给，超声振动的引入使麻花钻在旋转进给的基础上增加了轴向高频振动。因此，在Abaqus有限元仿真软件中对工件圆柱表面和底面施加完全固定，对麻花钻施加旋转位移载荷，载荷参数中进给速度为500 mm/min，旋转速度为3 141 rad/s；超声振动参数中振动频率为20 kHz，振动幅值为4 μm。
选取刀具几何表面和工件接触区网格表面建立通用接触，切向行为的罚函数中摩擦因数为0.3，法向行为中定义为“硬”接触，刀具与工件接触摩擦产生的热量分配为80%传入工件表面，20%传入刀具表面，磨损系数为1×10-7。
1.2　试验方案设计
HR-2抗氢钢深小孔钻削试验在UVAD试验系统上进行，试验采用的UVAD系统结构如图3（a）所示。系统包括数控机床、电能传输装置、换能器、超声刀柄、钻削刀具等。图3（b）为超声电源，可输出超声频率为1~50 kHz，最大输出功率为200 W。试验所用的UVAD系统谐振频率为29 kHz，波形为正弦波形，经功率计测得加工过程中输出功率约为170 W。为了研究HR-2抗氢钢深小孔钻削不同钻削深度时刀具磨损状态和孔壁粗糙度的影响规律，利用超景深显微镜观测刀具前后刀面及切削刃的磨损状态；抗氢钢工件先利用线切割机和金刚石线锯机切开，再利用3D表面光学轮廓仪对工件内孔壁加工表面进行三维几何形貌检测。
深小孔钻削试验采用的是由成都邦普切削刀具股份有限公司生产的TiAlN涂层不锈钢干切钻头（D2×45L1×D4×81L-GHSL1.5×30°），顶角为140°，螺旋角为30°。为保证孔壁加工表面的高洁净度，钻削过程中采用干式啄钻的加工方式，加工参数为主轴转速n=1 000 r/min；进给速度f=10 mm/min；单次进刀量0.1 mm。超声参数为振动频率为29 kHz；振动幅值A0=4 μm。钻削深度分别为10、20、30、40 mm时，利用超景深显微镜和扫描电子显微镜（Scanning Electron Microscope, SEM）观测刀具的磨损状态，并对磨损区域进行能谱分析（Energy Dispersive Spectroscopy,EDS）。基于3D表面光学轮廓仪获取孔壁三维表面形貌特征及粗糙度数据。
2　结果与分析
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HR-2抗氢钢深小孔钻削热力耦合仿真时，如图4所示。分别在工件孔壁内表面和刀具横刃、切削刃上设置路径，提取路径上的Mises应力、温度、磨损量等指标，获取深小孔钻削过程中刀具磨损状态、切削温度的变化趋势。通过对比UVAD和CD这2种钻削方式下的仿真结果，分析深小孔钻削中引入超声振动的影响规律。为了检验深小孔钻削有限元仿真结果的准确性，开展HR-2抗氢钢深小孔钻削试验，根据试验结果对有限元结果进行验证。
2.1　工件应力场、温度场有限元仿真
沿孔壁路径提取Mises应力、温度和等效塑性应变的结果如图5所示。钻削过程中刀具去除工件材料从而形成加工孔表面，接触阶段刀具瞬时挤压导致局部高塑性变形，同时产生大量摩擦热；离开阶段工件材料弹性变形持续恢复，叠加热应力形成残余应力和等效塑性应变（Plastic Equivalent Strain, PEEQ）峰值。随着钻削不断深入工件材料，切削热量积累导致沿钻削方向孔壁温度逐渐增大。相比于CD，UVAD降低了入口处的Mises应力，提高了出口处的应力，但是两者整体的应力值区别较小。施加高频超声振动后孔壁上温度值显著降低，等效塑性应变曲线波动幅值降低，表明引入超声振动可以有效降低切削热并改善散热条件，同时降低工件材料塑性流动从而提高孔壁加工质量。
2.2　刀具温度场、磨损量有限元仿真及试验
CD和UVAD这2种加工方式下刀具钻削区域的温度场分布特征如图6所示。由图6可知，CD加工时，切削温度的最高聚集点位于主切削刃与副切削刃过渡的刀尖圆弧段，对于UVAD加工时，最高温度出现在麻花钻钻尖部位。钻削过程中钻尖及横刃主要起挤压和定位作用，切削刃起剪切并去除材料作用。CD加工时，切削刃随着半径增大切削速度逐渐增大，单位时间内需要与更多的工件材料发生剪切摩擦，从而产生大量切削热，因此温度高于钻尖部位。引入超声振动将连续切削变为断续切削，减少了切削刃与工件摩擦的次数，从而降低了切削刃的温度，但钻尖部位在轴向挤压的基础上增加了高频的振动冲击，致使钻尖区域产生的热量增大。
提取麻花钻横刃和主切削刃沿刀具运动路径的温度及磨损量参数，如图7所示。由图7可知，随钻孔深度加深，横刃和主切削刃上的温度和磨损量均不断增大。引入超声振动对于横刃和主切削刃的磨损量的改善作用较为显著。UVAD可以有效降低主切削刃的温度尤其是在钻削初期对切削热的改善，但由于深小孔钻削时累积的切削热和恶劣的散热条件，钻削后期2种钻削方式主切削刃温度差异较小。
图8展示了深小孔加工过程中，UVAD与CD在不同深度时刀具横刃磨损特征的对比结果。通过超景深显微镜软件内置的面积测量功能获得横刃磨损面积随钻削进程的变化规律，如图9所示。由图8可知，刀具后刀面及横刃上覆盖的TiAlN涂层为棕黄色区域，在深小孔的钻削过程中横刃上的涂层逐渐磨损并露出涂层下的银白色刀具基体。由图9可知，在深小孔钻削初期横刃磨损最快，随着钻削深度的增大，横刃上的磨损面积逐渐增大且增大速度逐渐降低，引入超声振动后可以有效减缓横刃磨损。
图10展示了刀具后刀面与主切削刃的磨损特征。由图10可知，后刀面涂层上出现沿着刀具旋转速度走向的划痕，划痕下为银白色的刀具基体；主切削刃外沿存在约30~50 μm的不规则剥落坑。随着钻削深度增大，后刀面的涂层划痕和刃口钝化、崩刃现象愈加明显。钻削深度40 mm处可以观察到刃口后刀面附着条状凸起物，即刀具材料剥落导致刃口完整性急剧降低。施加超声振动使切削过程从连续接触变为间歇接触，减少了钻削产生的热量，降低涂层和基体热膨胀差异引发的剪切应力，后刀面边缘阶梯状断裂转为平滑过渡，有效减少主切削刃外沿的剥落面积，改善刃口完整性。
刀具前刀面及副切削刃的磨损形态结果如图11所示。由图11可知，CD加工时，前刀面涂层沿着排屑路线发生磨损，随着刀具钻削深入，涂层逐渐剥落；副切削刃上出现均匀磨损带，带宽随着钻削深度增大而增加；钻削深度30 mm时，在切削刃后方出现约150 μm×30 μm的剥落坑，坑内有多处平行于切削方向的划痕；钻削深度40 mm时，切削刃崩缺，基本丧失几何完整性；UVAD切削刃仍保持较好的完整性。以上结论均表明，随着钻削深度的增大，刀具磨损量逐渐增加，UVAD相较于CD可以有效降低刀具磨损，保持切削刃完整性，证明了有限元仿真结果的准确性和有效性。
图12展示了CD加工后不同钻削深度主切削刃的SEM观测图。由图12可知，钻削深度10~20 mm时，刀具表面形成黏结物，并存在明显黏结-剥落的痕迹。主切削刃磨损区域呈现出沟槽状划痕，刃尖钝化并产生微裂纹并蔓延至基体与涂层边界。以上观测结果表明，钻削初期切削温度相对较低，刀具主要在硬质颗粒的机械作用下发生磨损，刀具磨损以磨粒磨损和黏着磨损为主。
图13为图12（d）中刀具CD加工40 mm深度时的EDS分析结果图。由图13可知，刀具磨损区域无Ti元素，表面TiAlN涂层已完全磨损，暴露出以WC和Co为主要元素的刀具材料。月牙洼状磨损坑内出现Fe、Cr、Ni等元素，证明HR-2抗氢钢工件材料中的元素扩散至刀具主切削刃磨损表面。此外，EDS分析在磨损表面检测到明显的O元素富集，结合图12（d）SEM观测结果可见氧化物层及其破碎、剥落的形貌。由此表明，钻削中后期，随着钻削深度增加，加工区域散热条件恶化，切削热急剧积累导致温度显著升高，高温下工件材料向刀具的元素扩散和刀具自身与环境氧反应形成脆性氧化物层后剥离是导致材料流失的重要机制，刀具磨损形式由前期的机械磨损转变为以扩散磨损、氧化磨损为主的高温磨损。
2.3　加工表面三维形貌及表面粗糙度
加工孔加工表面三维形貌观测结果如图14（a）所示，沿孔轴向存在等间距蓝色凹陷带，反映啄钻过程的周期性载荷冲击。由于抗氢钢深小孔干式钻削过程中温度较高，由热软化效应和机械挤压引起塑性侧向流动效应和材料涂抹现象，因此能够在孔壁上观测到沿孔周向（钻头旋转方向）分布的带状隆起区，如图14（b）、图14（c）所示。钻削时产生的碎屑随着钻头旋转进给被碾压在孔壁上，由于高温的作用，碎屑在加工表面上发生微焊接从而出现了碎屑黏结的现象，如图14（d）所示。此外，高温还会导致工件材料软化，促进碎屑划擦加工表面，导致加工表面上出现硬质颗粒犁削的痕迹，如图14（e）所示。
通过在不同深度处测量多组加工表面粗糙度，得到如图15所示UVAD和CD表面粗糙度随钻削深度增加的变化示意图。由图15可知，2种钻削方式的孔壁粗糙度均随着钻削深度的增大而增大，引入超声振动后有效降低了粗糙度。进一步观测2种钻削方式后深小孔不同深度处孔壁的表面形貌，结果如图16所示。对于2种钻削方式，随着钻削深度的增加，不规则隆起区域面积占比增大，材料涂抹和侧向流动的痕迹更明显，发生更多的碎屑黏结。超声振动的引入优化了断屑排屑机制，碎屑黏结密度相比于CD有一定程度的降低。此外，断续切削有效降低切削温度，改善散热条件，从而抑制了材料软化和塑性流动；麻花钻轴向振动和旋转进给的复合运动改变了切屑运动规律，减少划痕叠加效应，从而降低了表面粗糙度。
3　结论
收起
本研究旨在通过热力耦合有限元仿真和钻削试验相结合的方法探究HR-2抗氢钢深小孔钻削过程中刀具磨损特征和加工表面形貌与质量的变化趋势，对比CD和UVAD这2种加工方式，分析引入超声振动对加工表面质量差、刀具磨损严重等问题的改善作用，得出的主要结论如下：
1）加工表面沿钻削深度的切削热积累导致孔壁温度逐渐增大。UVAD相较于CD，有效地降低了孔壁温度值和等效塑性应变曲线幅值，证明UVAD能够减少切削热并同时降低工件材料塑性流动。
2）引入超声振动将深小孔钻削过程中的连续切削变为断续切削，有效减少了刀具热量积累，改善了刀具磨损。试验结果显示，随着钻削深度的增大，CD刀具出现涂层剥落、刃口钝化崩刃等现象，但UVAD仍保持切削刃较高的完整性。
3）深小孔钻削过程中，加工区域散热条件随钻削深度增大而逐渐恶化，刀具磨损类型逐渐由以磨粒磨损、黏着磨损为主的机械磨损转变为以氧化磨损、扩散磨损为主的高温磨损。
4）深小孔加工孔壁内存在材料涂抹、磨粒黏结等问题，导致表面质量随着钻削深度的增大而恶化，UVAD抑制了材料软化和塑性流动，减少了碎屑黏结，从而有效降低了加工表面粗糙度，提高了加工表面质量。
基金
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  • 国家自然科学基金项目(52405517; 52475498)
文献
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2025年第47卷第9期
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doi: 10.16579/j.issn.1001.9669.2025.09.010
  • 接收时间：2025-06-16
  • 首发时间：2026-03-20
  • 出版时间：2025-09-15
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  • 收稿日期：2025-06-16
基金
National Natural Science Foundation of China(52405517; 52475498)
国家自然科学基金项目(52405517; 52475498)
作者信息
    1.大连理工大学 高性能精密制造全国重点实验室，大连　116024
    2.中国工程物理研究院 机械制造工艺研究所，绵阳　621900

通讯作者:

董志刚，男，1980年生，内蒙古赤峰人，博士，教授，博士研究生导师；主要研究方向为硬脆材料精密、超精密加工、多机器人融合智能制造、集成电路基片超精密加工；E-mail：。
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2种不同金属材料的力学参数
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Number of
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Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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