切削参数对新型光学铝级金刚石车削刀具磨损的影响

光学器件和光学测量系统的关键部件主要通过超精密加工制造。铝合金具有很多优势，通常用于光子产业。光学领域对铝合金使用和需求的不断增加，促进了在铸造过程中采用快速凝固技术对铝合金等级重新改良的发展。优异的微观结构和改进的机械和物理性能是新型铝合金等级的特点。目前主要问题在于采用金刚石车削时，由于在切削性方面缺乏对铝合金性能的充分研究，导致机械加工数据库非常有限。本文通过改变金刚石的切削参数，测量切齿安装距超过4km时金刚石刀具的磨损，研究了快速凝固铝合金RSA 905的切削性能。改变的机械加工参数为切削速度、进给速度和切削深度。结果表明切削速度对金刚石刀具的磨损影响最大。主轴转速为500rpm、进给速度为25mm/min、切削深度为15μm时，刀具磨损达到最大值12.2μm；主轴转速为1750rpm、进给速度为5mm/min、切削深度为5μm时，刀具磨损达到最小值2.45μm。通常，较高的切削速度、较低的进给速度和较短的切削深度的组合可以减少金刚石刀具磨损。建立了模型统计以分析金刚石刀具磨损。通过该模型可以生成磨损图，从而确定切削参数产生最小磨损的区域。结果证明，快速凝固铝是更好的选择，为机械工程师使用这种材料提供了参考。

Effect of cutting parameters on tool wear in diamond turning of new optical aluminium grade

Critical components in optical devices and optical measuring systems are mainly produced through the ultra-high precision machining. Aluminium alloys have been proven to be advantageous and very commonly used in the photonics industry. This ever-increasing use and demand in optics have led to the development of newly modified grades of aluminium alloys produced by rapid solidification in the foundry process. The newer grades are characterised by the finer microstructures and can improve mechanical and physical properties. Their main inconvenience currently lies in their having a very limited machining database as there is not enough adequate research contributions on their performance in terms of machinability when diamond turned. This paper investigates the machinability of rapidly solidified aluminium RSA 905 by varying diamond cutting parameters and measuring the diamond tool wear over a cutting distance of 4km. The machining parameters varied were cutting speed, feed rate and depth of cut. The results show that the cutting speed is the most influential parameter on the diamond tool wear. The highest tool wear of 12.2μm was achieved at the spindle speed of 500rpm, the feed rate of 25mm/min and the depth of cut of 15μm. The lowest tool wear of 2.45μm was recorded at the spindle of 1750rpm speed, the feed rate of 5mm/min and the depth of cut of 5μm. Generally, a combination of higher cutting speeds, lower feed rates and smaller depths of cut caused less diamond tool wear. Statistical analysis was performed to develop a model for the diamond tool wear. Wear maps were generated from the model to identify zones where the cutting parameters produced the least wear. The results prove the rapidly solidified aluminium is a superior alternative to traditional aluminium alloys and can also provide a reference for machinists using this material.