碳纤维增强树脂基复合材料(CFRP)具有优越的物理和力学性能,已在航空制造工业中得到大量应用.在主承力结构中,CFRP与金属材料的连接通常为机械连接.然而,CFRP的各向异性严重影响了其制孔质量.由于CFRP和金属具有截然不同的材料属性,CFRP/金属叠层结构制孔技术成为飞机装配过程中的一大难题.本文首先阐述了CFRP及其叠层结构在切削过程中的切屑形成机制、钻削力和钻削热的研究现状;其次,剖析了钻削过程中典型加工损伤,如毛刺与撕裂、分层缺陷及孔壁表面损伤的产生原因和影响因素;然后,介绍了CFRP制孔刀具材料和几何结构的优化设计研究进展,并综述了螺旋铣孔、变工艺参数钻削、“以磨代钻”和振动辅助制孔等多种CFRP及其叠层结构加工新技术及钻削过程的仿真研究.最后,借鉴钎焊工具和超声振动技术的独特优势,提出了磨粒有序排布钎焊金刚石工具的超声振动加工构想,以达到CFRP及其叠层结构的精密高效制孔加工这一目的.
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