曲轴磨削工艺与残余应力关系
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摘要
对曲轴磨削过程中影响曲轴表面残余应力变化的几个磨削参量进行研究,分析不同参数变化对曲轴圆角和侧台残余应力分布的影响规律.结果表明:磨削速度、磨削进给量和磨削余量对曲轴圆角残余应力影响较小,对侧台残余应力影响较大.侧台残余应力随磨削速度的增大而减小,随磨削进给量和磨削余量的增加而增大.侧台残余应力在深度方向呈先增大后减小的趋势,侧台残余应力为拉应力,在一定深度拉应力下转变为压应力.当磨削速度为100 m/s、进给量为0.45 mm/r且磨削余量为0.35 mm时,残余应力峰值最小,约为250 MPa;当磨削速度为90 m/s、进给量为0.90 mm/r且磨削余量为0.35 mm时,残余应力峰值为1 200 MPa.材料去除量与残余应力峰值呈正比关系,单位时间内材料去除量越大,残余拉应力越大.
Several grinding parameters affecting the residual stress on the crankshaft surface were researched,and the influence of different parameters on the residual stress distribution of crankshaft fillet,journal and side step was analyzed. The results show that the influence of grinding speed,grinding feed rate and grinding allowance on the residual stress of fillet is weak,but the influence on the residual stress of side step is great. The residual stress of side step decreases with increasing grinding speed and increases with increasing grinding feed and grinding allowance. The residual stress of the side step first increases and then decreases in the depth direction. The residual stress of the subsurface is tensile stress. The residual stress changes into compressive stress at a certain depth. Furthermore,when the grinding speed is 100 m/s,the feed rate is 0.45 mm/r and the grinding allowance is 0.35 mm,the peak residual stress value is about 250 MPa. When the grinding speed is 90 m/s,the feed rate is 0.90 mm/r and the grinding allowance is0.35 mm,the peak residual stress value is 1 200 MPa. It is also found that the amount of material removal is directly proportional to the peak value of residual stress. The greater the material removal amount per unit time,the greater the residual tensile stress.
Several grinding parameters affecting the residual stress on the crankshaft surface were researched,and the influence of different parameters on the residual stress distribution of crankshaft fillet,journal and side step was analyzed. The results show that the influence of grinding speed,grinding feed rate and grinding allowance on the residual stress of fillet is weak,but the influence on the residual stress of side step is great. The residual stress of side step decreases with increasing grinding speed and increases with increasing grinding feed and grinding allowance. The residual stress of the side step first increases and then decreases in the depth direction. The residual stress of the subsurface is tensile stress. The residual stress changes into compressive stress at a certain depth. Furthermore,when the grinding speed is 100 m/s,the feed rate is 0.45 mm/r and the grinding allowance is 0.35 mm,the peak residual stress value is about 250 MPa. When the grinding speed is 90 m/s,the feed rate is 0.90 mm/r and the grinding allowance is0.35 mm,the peak residual stress value is 1 200 MPa. It is also found that the amount of material removal is directly proportional to the peak value of residual stress. The greater the material removal amount per unit time,the greater the residual tensile stress.
引文
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[10]胡忠辉,袁哲俊,高峰.磨削力对磨削表面层质量的影响的试验研究[J].磨料磨具与磨削,1988,6(48):4-9.
[11]Tian L,Fu Y C,Xu J H,et al.The influence of speed on material removal mechanism in high speed grinding with single grit[J].International Journal of Machine Tools&Manufacture,2015,89:192-201.
[12]Xu Y Q,Zhang T,Bai Y M.Analysis of the surface residual stress in grinding Aermet100[J].Materials Science Forum,2012,704-705:318-324.
[13]Balart M J,Bouzina A,Edwards L,et al.The onset of tensile residual stresses in grinding of hardened steels[J].Materials Science and Engineering A,2004,367:132-142.
[14]Nbuyen T,Liu M,Zhang L C,et al.An investigation of the grinding-hardening induced by traverse cylindrical grinding[J].Journal of Manufacturing Science and Engineering,2014,136(5):051008-051017.
[15]Chen X,Rowe W B,Mccormack D F.Analysis of the transitional temperature for tensile residual stress in grinding[J].Journal of Materials Processing Technology,2000,107:216-221.
[16]Grum J.A review of the influence of grinding conditions on resulting residual stresses after induction surface hardening and grinding[J].Journal of Materials Processing Technology,2001,114:212-226.
[2]胡忠辉,袁哲俊.磨削残余应力产生机理的研究[J].哈尔滨工业大学学报,1989,6(3):51-60.
[3]方华,高峥,袁兆成,等.淬火强化曲轴的弯曲疲劳分析[J].内燃机学报,2003,21(6):467-472.
[4]刘莉娟.磨削表面残余应力控制及零件表面完整性实验研究[D].沈阳:东北大学机械工程与自动化学院,2012.
[5]贾亚凯,李静,沈南燕,等.基于Deform 3D对磨削表面残余应力的仿真研究[J].精密制造与自动化,2015,2:7-10.
[6]孔德军,孙波,朱伟,等.曲轴圆角残余应力的XRD试验研究[J].内燃机学报,2008,26(6):89-92.
[7]Martell J J,Liu C R,Shi J.Experimental investigation on variation of machined residual stresses by turning and grinding of hardened AISI 1053 steel[J].The International Journal of Advanced Manufacturing Technology,2014,74:1381-1392.
[8]Pala Z,Ganev N.The impact of various cooling environments on the distribution of macroscopic residual stresses in near-surface layers of ground steels[J].Materials Science and Engineering A,2008,497:200-205.
[9]Liu M,Nguyen T,Zhang L C,et al.Effect of grinding-induced cyclic heating on the hardened layer generation in the plunge grinding of a cylindrical component[J].International Journal of Machine Tools&Manufacture,2015,89:55-63.
[10]胡忠辉,袁哲俊,高峰.磨削力对磨削表面层质量的影响的试验研究[J].磨料磨具与磨削,1988,6(48):4-9.
[11]Tian L,Fu Y C,Xu J H,et al.The influence of speed on material removal mechanism in high speed grinding with single grit[J].International Journal of Machine Tools&Manufacture,2015,89:192-201.
[12]Xu Y Q,Zhang T,Bai Y M.Analysis of the surface residual stress in grinding Aermet100[J].Materials Science Forum,2012,704-705:318-324.
[13]Balart M J,Bouzina A,Edwards L,et al.The onset of tensile residual stresses in grinding of hardened steels[J].Materials Science and Engineering A,2004,367:132-142.
[14]Nbuyen T,Liu M,Zhang L C,et al.An investigation of the grinding-hardening induced by traverse cylindrical grinding[J].Journal of Manufacturing Science and Engineering,2014,136(5):051008-051017.
[15]Chen X,Rowe W B,Mccormack D F.Analysis of the transitional temperature for tensile residual stress in grinding[J].Journal of Materials Processing Technology,2000,107:216-221.
[16]Grum J.A review of the influence of grinding conditions on resulting residual stresses after induction surface hardening and grinding[J].Journal of Materials Processing Technology,2001,114:212-226.