损伤力学在重型切削硬质合金刀具失效分析中的应用探讨
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摘要
为研究刀具失效的微细观本质问题,首先在对损伤力学基本理论及应用分析的基础上,探究重型切削过程中大型工件材料属性与加工技术特性对刀具损伤的影响;然后对硬质合金材料损伤特性与刀具损伤失效进行探讨,明确重型切削硬质合金刀具失效与损伤过程存在密切关系;最后基于重型切削载荷特性与刀具损伤属性提出刀具材料损伤失效的具体研究方向及方法。通过应用损伤力学对刀具进行失效分析,不仅能完善刀具失效具体过程,还可为刀具寿命预测及设计开发等提供理论依据。
In order to study the micro-meso essential problem of tool failure,firstly,based on the analysis of damage mechanics basic theory and application,the influence of material properties and machining technology characteristics of heavy parts on tool damage is explored in heavy cutting process. Then,the damage characteristics of cemented carbide material and the damage and failure of tool are discussed,it is concluded that the failure of cemented carbide tool is closely related to the damage process; finally,the concrete research direction and method of tool damage failure are put forward based on the characteristics of heavy cutting load and the damage property of tool material. Through the failure analysis of tool by applying damage mechanics can not only improve the specific process of tool failure,but also provide a theoretical basis for tool life prediction and design development.
In order to study the micro-meso essential problem of tool failure,firstly,based on the analysis of damage mechanics basic theory and application,the influence of material properties and machining technology characteristics of heavy parts on tool damage is explored in heavy cutting process. Then,the damage characteristics of cemented carbide material and the damage and failure of tool are discussed,it is concluded that the failure of cemented carbide tool is closely related to the damage process; finally,the concrete research direction and method of tool damage failure are put forward based on the characteristics of heavy cutting load and the damage property of tool material. Through the failure analysis of tool by applying damage mechanics can not only improve the specific process of tool failure,but also provide a theoretical basis for tool life prediction and design development.
引文
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[6]Jawaidy A,Sharif S,Koksal S.Evaluation of wear mechanisms of coated carbide tools when face milling titanium alloy[J].Journal of Materials Processing Technology,2000,99(1):266-274.
[7]Melo Anderson C A de,Milan Júlio César G,Silva Márcio B da,et al,Some observations on wear and damages in cemented carbide tools[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2006,28(3):269.
[8]Kapoor SG,DeV or RE.Microstructure-level model for the prediction of tool failure in coated WC-Co cutting tool materials during intermittent cutting[J].Journal of Manufacturing Science and Engineering,2007,129(5):893-901.
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[14]Kim CS,Massa TR,Rohrer GS.Modeling the relationship between microstructural features and the strength of WC-Co composites[J].International Journal of Refractory Metals and Hard Materials,2006,24(1-2):89-100.
[15]李杰,任晓丹.混凝土随机损伤力学研究进展[J].建筑结构学报,2014(4):20-29.
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[17]李念,陈普会.复合材料层合板低速冲击损伤分析的连续介质损伤力学模型[J].力学学报,2015,47(3):458-470.
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[21]Usik Lee,George A Lesieutre,Lei Fang.Anisotropic damage mechanics based on strain energy equivalence and equivalent elliptical microcracks[J].International Journal of Solids and Structures,1997,34(33-34):4377-4397.
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[25]程耀楠,钱俊,卢真真,等.核电水室封头高效切削加工及刀具失效分析[J].哈尔滨理工大学学报,2014,19(5):50-55.
[26]严复钢,何耿煌,刘献礼.极端重载条件下高效切削刀具技术[J].哈尔滨理工大学学报,2011,16(6):11-16.
[27]Yaonan Cheng,Liu Li,Zhenzhen Lu,Rui Guan,Tong Wang.Study on the adhering failure mechanism of cemented carbide inserts and element diffusion model during the heavy-duty cutting of water chamber head[J].The International Journal of Advanced Manufacturing Technology,2015,89(9-12):1833-1842.
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[32]Owen D R J,Vaz Jr M.Computational techniques applied to highspeed machining under adiabatic strain localization condition[J].Computer Methods in Applied Mechanics and Engineering,1999,171(3-4):445-461.
[33]Vaz Jr M,Owen D R J,Kalhori V,et al.Modelling and simulation of machining processes[J].Archives of Computational Methods in Engineering,2007,14(2):173-204.
[34]李壮,王家君.WC-Co超细硬质合金微观结构对其性能的影响[J].硬质合金,2009,26(3):188-193.
[35]刘寿容.WC-Co硬质合金的性能与成分和显微结构的关系[J].理化检验-物理分册,2003,39(2):70-74.
[36]Sun L,Yang T,Jia C,et al.VC,Cr3C2 doped ultrafine WC-Co cemented carbides prepared by spark plasma sintering[J].International Journal of Refractory Metals&Hard Materials,2011,29(2):147-152.
[37]王东,赵军,李安海.WC-Co硬质合金微观结构随机分布模型与弹性性能预报[J].材料热处理学报,2013,34(3):160-164.
[38]Park S.Development of amicrostructure-level finite element model for the prediction of tool failure by chipping in WC-Co systems[D].Illinois:University of Illinois at Urbana-Champaign,2007.
[2]李振加,顾祖慰.铣削过程刀具破损原因的探讨[J].机械工程学报,1993,29(4):93-96.
[3]赵云振,党庆波,李广慧,等.硬质合金刀具断续切削破损原因的探讨[J].煤炭技术,1998(1):8-10.
[4]Ezugwu EO,Okeke CI.Tool life and wear mechanisms of TiN coated tools in an intermittent cutting operation[J].Journal of Materials Processing Technology,2001,116(1):10-15.
[5]Urbanski JP,Koshy P,Dewes RC,et al.High speed machining of moulds and dies for netshape manufacture[J].Materials&Design,2000,21(4):395-402.
[6]Jawaidy A,Sharif S,Koksal S.Evaluation of wear mechanisms of coated carbide tools when face milling titanium alloy[J].Journal of Materials Processing Technology,2000,99(1):266-274.
[7]Melo Anderson C A de,Milan Júlio César G,Silva Márcio B da,et al,Some observations on wear and damages in cemented carbide tools[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2006,28(3):269.
[8]Kapoor SG,DeV or RE.Microstructure-level model for the prediction of tool failure in coated WC-Co cutting tool materials during intermittent cutting[J].Journal of Manufacturing Science and Engineering,2007,129(5):893-901.
[9]崔晓斌.高速断续切削淬硬钢刀具失效机理研究[D].济南:山东大学,2013.
[10]范小宁,徐格宁,杨瑞刚.基于损伤-断裂力学理论的起重机疲劳寿命估算方法[J].中国安全学报,2011(9):58-63.
[11]周胜田.航空发动机叶片疲劳的损伤力学研究及外物损伤影响[D].沈阳:东北大学,2007.
[12]邬华芝.钛合金焊接接头疲劳损伤模型[D].南京:南京航空航天大学,2003.
[13]Kim CS.Microstructural-mechanical property relation-ships in WC-Co composites[D].Pittsburgh:Carnegie Mellon University,2004.
[14]Kim CS,Massa TR,Rohrer GS.Modeling the relationship between microstructural features and the strength of WC-Co composites[J].International Journal of Refractory Metals and Hard Materials,2006,24(1-2):89-100.
[15]李杰,任晓丹.混凝土随机损伤力学研究进展[J].建筑结构学报,2014(4):20-29.
[16]冯西桥.脆性材料的细观损伤理论和损伤结构的安定分析[D].北京:清华大学,1995.
[17]李念,陈普会.复合材料层合板低速冲击损伤分析的连续介质损伤力学模型[J].力学学报,2015,47(3):458-470.
[18]张志远,黄西成.变形路径对金属塑性损伤的影响[J].四川大学学报,2003,40(4):719-723.
[19]PaeP egem WV,Degrieck J.Simulating damage and permanent strain in composites under in-plane fatigue loading[J].Computers and Structures,2005,83(2):1930-1942.
[20]Sandeep Kumar,Niranjan Roy,Ranjan Ganguli.Monitoring low cycle fatigue damage in turbine blade using vibration characteristics[J].Mechanical Systems and Signal Processing,2007,21(1):480-501.
[21]Usik Lee,George A Lesieutre,Lei Fang.Anisotropic damage mechanics based on strain energy equivalence and equivalent elliptical microcracks[J].International Journal of Solids and Structures,1997,34(33-34):4377-4397.
[22]MandlbortB B.The Fractal Geomey of Natutre[D].San Frnciseo:Fereman,1982.
[23]谢和平.脆性材料中的分形损伤[J].机械强度,1995,17(2):75-82.
[24]谢和平,鞠杨.分维数空间中的损伤力学初探[J].力学学报,1999,31(3):300-310.
[25]程耀楠,钱俊,卢真真,等.核电水室封头高效切削加工及刀具失效分析[J].哈尔滨理工大学学报,2014,19(5):50-55.
[26]严复钢,何耿煌,刘献礼.极端重载条件下高效切削刀具技术[J].哈尔滨理工大学学报,2011,16(6):11-16.
[27]Yaonan Cheng,Liu Li,Zhenzhen Lu,Rui Guan,Tong Wang.Study on the adhering failure mechanism of cemented carbide inserts and element diffusion model during the heavy-duty cutting of water chamber head[J].The International Journal of Advanced Manufacturing Technology,2015,89(9-12):1833-1842.
[28]何耿煌.大型筒节零件高效切削及刀具技术研究[D].哈尔滨:哈尔滨理工大学,2013.
[29]刘献礼,刘铭,何耿煌,等.重型切削过程硬质合金刀片的冲击破损行为[J].机械工程学报,2014,50(23):175-185.
[30]Uhlmann E,von der Schulenburg M G,Zettier R.Finite element modeling and cutting simulation of inconel 718[J].CIRP Annals-Manufacturing Technology,2007,56(1):61-64.
[31]Mabrouki T,Girardin F,Asad M,et al.Numerical and experimental study of dry cutting for an acronautic aluminum alloy(A2024-T351)[J].International Journal of Machine Tools and Manufacture,2008,48(11):1187-1197.
[32]Owen D R J,Vaz Jr M.Computational techniques applied to highspeed machining under adiabatic strain localization condition[J].Computer Methods in Applied Mechanics and Engineering,1999,171(3-4):445-461.
[33]Vaz Jr M,Owen D R J,Kalhori V,et al.Modelling and simulation of machining processes[J].Archives of Computational Methods in Engineering,2007,14(2):173-204.
[34]李壮,王家君.WC-Co超细硬质合金微观结构对其性能的影响[J].硬质合金,2009,26(3):188-193.
[35]刘寿容.WC-Co硬质合金的性能与成分和显微结构的关系[J].理化检验-物理分册,2003,39(2):70-74.
[36]Sun L,Yang T,Jia C,et al.VC,Cr3C2 doped ultrafine WC-Co cemented carbides prepared by spark plasma sintering[J].International Journal of Refractory Metals&Hard Materials,2011,29(2):147-152.
[37]王东,赵军,李安海.WC-Co硬质合金微观结构随机分布模型与弹性性能预报[J].材料热处理学报,2013,34(3):160-164.
[38]Park S.Development of amicrostructure-level finite element model for the prediction of tool failure by chipping in WC-Co systems[D].Illinois:University of Illinois at Urbana-Champaign,2007.