加工含镍球墨铸铁时刀具磨损机理的研究
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摘要
本文分析了轧辊的工作条件、轧辊的性能要求及轧辊的化学成分和金相组织,并对轧辊铸造中应该注意的问题和轧辊的技术要求进行了分析。利用有限元法研究了Al_2O_3/TiC梯度功能陶瓷刀具材料的抗热震性能。对无镍球墨铸铁、低镍球墨铸铁、高镍球墨铸铁三种轧辊进行切削试验,研究了Al_2O_3/TiC梯度陶瓷刀具的寿命及磨损、破损机理。
采用有限元软件ANSYS对激光热冲击条件下,Al_2O_3/TiC梯度功能陶瓷刀具材料的瞬态温度场及热应力场进行了仿真研究,并与均质陶瓷进行对比,结果表明:Al_2O-3/TiC梯度功能陶瓷刀具材料抗热震性能优于均质陶瓷。
对无镍球墨铸铁、低镍球墨铸铁、高镍球墨铸铁三种轧辊进行了切削试验,结果表明:Al_2O_3/TiC梯度功能陶瓷刀具与YS10相比拥有更长的刀具使用寿命;在150m/min速度下加工低镍球墨铸铁时,Al_2O_3/TiC梯度陶瓷刀具磨损形态主要为后刀面磨损;加工高镍球墨铸铁时,刀具磨损形态主要为前刀面磨损。较低速度(75m/min)下切削高镍球墨铸铁,Al_2O_3/TiC梯度陶瓷刀具的磨损形态以后刀面磨损为主;较高速度(250m/min)下切削高镍球墨铸铁,刀具的破损形态以前刀面片状剥落和刀尖微崩刃为主。
The working environment, performance requirements, chemical composition and metallographical structure were analysed firstly. The technical requirements on roller casting was also clearified. Thermal shock resistance of Al_2O_3 /TiC gradient ceramic was simulated by FEM. The tool life and wear mechanisms was inrestigated when the new tool machining cast irons with no, low and high Ni centent.
Transient temperature field and thermal stress field under laser shock of Al_2O_3 /TiC gradient ceramic were simulted by ANSYS. The results show that thermal shock resistance of Al_2O_3/TiC gradient ceramic is superior to the homogeneous ceramic.
By machining cast irons with no, low and high Ni centent, the results show that Al_2O_3/TiC gradient ceramic tool is superior to cemented carbide tool YS10 under the same condition. At the cutting speed of 150m/min, the mainly fracture mode is flank wear when machining cast irons with low Ni content, the main fracture mode becomes rake face wear when machining cast Irons with high Ni content. At the low cutting speed (75m/min), the main fracture mode is flank wear; at the high cutting speed (250 m/min), the main breakage mode is rake face spalling and tool nose chipping.
采用有限元软件ANSYS对激光热冲击条件下,Al_2O_3/TiC梯度功能陶瓷刀具材料的瞬态温度场及热应力场进行了仿真研究,并与均质陶瓷进行对比,结果表明:Al_2O-3/TiC梯度功能陶瓷刀具材料抗热震性能优于均质陶瓷。
对无镍球墨铸铁、低镍球墨铸铁、高镍球墨铸铁三种轧辊进行了切削试验,结果表明:Al_2O_3/TiC梯度功能陶瓷刀具与YS10相比拥有更长的刀具使用寿命;在150m/min速度下加工低镍球墨铸铁时,Al_2O_3/TiC梯度陶瓷刀具磨损形态主要为后刀面磨损;加工高镍球墨铸铁时,刀具磨损形态主要为前刀面磨损。较低速度(75m/min)下切削高镍球墨铸铁,Al_2O_3/TiC梯度陶瓷刀具的磨损形态以后刀面磨损为主;较高速度(250m/min)下切削高镍球墨铸铁,刀具的破损形态以前刀面片状剥落和刀尖微崩刃为主。
The working environment, performance requirements, chemical composition and metallographical structure were analysed firstly. The technical requirements on roller casting was also clearified. Thermal shock resistance of Al_2O_3 /TiC gradient ceramic was simulated by FEM. The tool life and wear mechanisms was inrestigated when the new tool machining cast irons with no, low and high Ni centent.
Transient temperature field and thermal stress field under laser shock of Al_2O_3 /TiC gradient ceramic were simulted by ANSYS. The results show that thermal shock resistance of Al_2O_3/TiC gradient ceramic is superior to the homogeneous ceramic.
By machining cast irons with no, low and high Ni centent, the results show that Al_2O_3/TiC gradient ceramic tool is superior to cemented carbide tool YS10 under the same condition. At the cutting speed of 150m/min, the mainly fracture mode is flank wear when machining cast irons with low Ni content, the main fracture mode becomes rake face wear when machining cast Irons with high Ni content. At the low cutting speed (75m/min), the main fracture mode is flank wear; at the high cutting speed (250 m/min), the main breakage mode is rake face spalling and tool nose chipping.
引文
1.杨怀林,吉安昌.镍钼球墨铸铁轧辊生产实践[J].特钢技术,2006(1):43-45.
2.中华人民共和国国家标准.GB/T1504-91铸铁轧辊[Z].
3.刘金城,孙国雄.国外ADI的最新进展[J].现代铸铁,2003(3):125.
4.王泽华.等温淬火球铁(ADI)的研究和应用[J].机车车辆工艺,2003(4):125.
5.魏秉庆,梁吉,吴德海著.贝氏体球墨铸铁[M].北京:机械工业出版社,2001.
6.郭旭红,陈澄洲.奥贝球墨铸铁切削加工性能的试验研究[J].工具技术,1996,30(11):125.
7.杜国臣,干式切削刀具及其在加工轧辊中的应用[J].煤矿机械,2006,27(3):470-472.
8.郭旭红,陈澄洲,刘军,奥贝球墨铸铁切削机理的研究[J].机械工程材料,1997,21(5):30-32.
9.Pashby I R,W allbank,J.Ceram,ic too Iwear when roach ining ofaustempered ductile iron[J].Wear,1993,22-33.
10.Little fajr G.,Smith G T,Math inability of austempered ductileiron[C].Current Issue,1997 To Be Published.
11.Seah K H W,Sharma S C.Math inability of alloyed austem2pered ductile iron[J].International Journal of Machine Tools Manufacture,1995,35(10):1475-1479.
12.Goldberg M,Smith G T,Berry J T,et al.Math inability assess2ment and surface integrity characteristics of austempered duc2tile iron(ADI) using uitra2hard cutting tools[C].Third Interna2tional Machining and Grinding Conference,SM E,October1999,Ohio USA,825-846.
13.刘战强,艾兴.高速切削刀具磨损表面形态研究[J].摩擦学学报,2002,22(6):468-471.
14.刘有荣,刘家浚,朱宝亮,Si_3N_4基陶瓷刀具的摩擦磨损规律与机理分析[J],摩擦学学报,1997,12(2):105-114.
15.邓建新,张希华,李剑峰等.TiB_2增强陶瓷Al_2O_3刀具高速切削摩擦磨损性能[J],摩擦学学报,2004,24(3):197-201.
16.邓建新,艾兴,冯益华,陶瓷刀具切削加工时的磨损和润滑及其加工对象的匹配研究[J].机械工程学报,2002,38(4):40-45.
17.王宇,胡景姝等,PCBN刀具技术最新进展[J].工具技术,2006,(40):15-17.
18.刘献礼,肖露,PCBN刀具的发展性能及应用[J].现代制造工程,2002(1):37-39.
19.苗志毅,冯克明,绿色切削与PCBN刀具切削技术[J].金刚石与磨料磨具工程,2004(5):73-76.
20.张铁铭,干式切削及其所用刀具材料的现状[J].工具展望,2003(5):1-4.
21.谢国如,岑向东等.PCBN刀具在干切削中的应用研究[J].机械工程师,2006(2):82-83.
22.邱小林.Ti(C,N)基金属陶瓷的研究进展[J].材料导报,2006(20):420-423.
23.曹玉军,刘杰.SiC品须增韧WC陶瓷刀具材料的研究[J].稀有金属与硬质合金,2005,33(4):13-16.
24.邹斌,黄传真等.氮化硅基陶瓷刀具材料力学性能和显微结构的研究[J].工具技术,2006,40(2):12-15.
25.谢国如,张兴国等.氮化硅陶瓷刀具的性能及其应用[J].工具技术,2006,41(2):78-80.
26.陈文琳,李伟等.Ti(C,N)基金属陶瓷刀具切削加工有限元模拟[J].硬质合金,2006,23(4):248-252.
27.江玉和.非金属材料化学[M].北京:科学技术文献出版社,1992
28.成云平,王淑华等.纳米材料在陶瓷刀具中的应用现状[J].超硬材料工程,2006,18(4):41-44.
29.曹同坤,邓建新.自润滑陶瓷刀具切削过程中的减摩机理研究[J].硅酸盐学报,2006,34(10):1232-1237.
30.郭旭红,芮延年,朱圣领,董桂岩.陶瓷刀具干切削等温淬火球铁(ADI)的磨损机理研究[J].摩擦学学报,2006,26(1):73-78.
31.吴少华,郭旭红.陶瓷刀具高速干切削等温淬火球铁(ADI)磨损性能研究[J].润滑与密封,2006,10:141-144.
32.石增敏,郑勇,刘文俊等.Ti(C,N)基金属陶瓷刀具的切削性能[J].中国有色金属学报,2006,16(5):805-810.
33.邓新建,艾兴,冯益华.陶瓷刀具切削加工时的磨损和润滑及其加工对象的匹配研究[J].机械工程学报,2002,38(4):40-45.,
34.Zackrisson J,Rolander U,Weinl G,et al.Microstructure of the Surface Zone in a Heat Treated Cermet Material[J].Int J Refr Met Hard Mater,1998,16:315-322.
35.钟金豹,黄传真等.纳米复相陶瓷刀具材料的研究现状[J].现代制造技术与装备,2006,4:17-21.
36 新野正之.功能梯度材料研究[J].日本复合材料学会志.1987,14(5):257.
37 洪长青,韩杰才,张幸红等.TiB_2-Cu复合材料热冲击损伤行为的数值模拟,稀有金属材料与工程.2006,1(1)
38.熊智军,赵熹华,李永强等.激光深熔焊接热源模型的研究进展[J].焊接,2006(12):12-16
39.莫立春,钱百年,国旭明等.焊接热源计算模式的研究进展[J].焊接学报,2001,22(3):93-96
40.蔡志鹏,赵海燕,鹿安理等.焊接数值模拟中分段移动热源模型的建立及应用[J].机械工程学报,2002,13(3):208-210
41.薛忠明,顾兰,张彦华.激光焊接温度场数值模拟[J].焊接学报.2003,24(2):79-82
42.曾祥呈,黄健文,张庆茂.激光焊接过程温度场的模拟[J].应用激光.2008(28):3
43.Shigreru Akiyama,Shigeyasu Amada.The thermal shock strength of Al_2O_3 by laser irradiation method.Ceramics International.2001(27):171-177
44.I.Tanishita,Heat Transfer,shoukabo press,Japan,1988,pp:155-156
45.Ceram.Soc.Japan,Mechanical properties of ceramics,Japanese Ceram.Soc,1988,PP.23-25
46.M.Itou,K.Ueda,T.sugita,Fracture mecha ics analysis of thermal shock cracking of ceramics in laser heating,J.Soc.prec.Eng.1990(58):1487-1492
2.中华人民共和国国家标准.GB/T1504-91铸铁轧辊[Z].
3.刘金城,孙国雄.国外ADI的最新进展[J].现代铸铁,2003(3):125.
4.王泽华.等温淬火球铁(ADI)的研究和应用[J].机车车辆工艺,2003(4):125.
5.魏秉庆,梁吉,吴德海著.贝氏体球墨铸铁[M].北京:机械工业出版社,2001.
6.郭旭红,陈澄洲.奥贝球墨铸铁切削加工性能的试验研究[J].工具技术,1996,30(11):125.
7.杜国臣,干式切削刀具及其在加工轧辊中的应用[J].煤矿机械,2006,27(3):470-472.
8.郭旭红,陈澄洲,刘军,奥贝球墨铸铁切削机理的研究[J].机械工程材料,1997,21(5):30-32.
9.Pashby I R,W allbank,J.Ceram,ic too Iwear when roach ining ofaustempered ductile iron[J].Wear,1993,22-33.
10.Little fajr G.,Smith G T,Math inability of austempered ductileiron[C].Current Issue,1997 To Be Published.
11.Seah K H W,Sharma S C.Math inability of alloyed austem2pered ductile iron[J].International Journal of Machine Tools Manufacture,1995,35(10):1475-1479.
12.Goldberg M,Smith G T,Berry J T,et al.Math inability assess2ment and surface integrity characteristics of austempered duc2tile iron(ADI) using uitra2hard cutting tools[C].Third Interna2tional Machining and Grinding Conference,SM E,October1999,Ohio USA,825-846.
13.刘战强,艾兴.高速切削刀具磨损表面形态研究[J].摩擦学学报,2002,22(6):468-471.
14.刘有荣,刘家浚,朱宝亮,Si_3N_4基陶瓷刀具的摩擦磨损规律与机理分析[J],摩擦学学报,1997,12(2):105-114.
15.邓建新,张希华,李剑峰等.TiB_2增强陶瓷Al_2O_3刀具高速切削摩擦磨损性能[J],摩擦学学报,2004,24(3):197-201.
16.邓建新,艾兴,冯益华,陶瓷刀具切削加工时的磨损和润滑及其加工对象的匹配研究[J].机械工程学报,2002,38(4):40-45.
17.王宇,胡景姝等,PCBN刀具技术最新进展[J].工具技术,2006,(40):15-17.
18.刘献礼,肖露,PCBN刀具的发展性能及应用[J].现代制造工程,2002(1):37-39.
19.苗志毅,冯克明,绿色切削与PCBN刀具切削技术[J].金刚石与磨料磨具工程,2004(5):73-76.
20.张铁铭,干式切削及其所用刀具材料的现状[J].工具展望,2003(5):1-4.
21.谢国如,岑向东等.PCBN刀具在干切削中的应用研究[J].机械工程师,2006(2):82-83.
22.邱小林.Ti(C,N)基金属陶瓷的研究进展[J].材料导报,2006(20):420-423.
23.曹玉军,刘杰.SiC品须增韧WC陶瓷刀具材料的研究[J].稀有金属与硬质合金,2005,33(4):13-16.
24.邹斌,黄传真等.氮化硅基陶瓷刀具材料力学性能和显微结构的研究[J].工具技术,2006,40(2):12-15.
25.谢国如,张兴国等.氮化硅陶瓷刀具的性能及其应用[J].工具技术,2006,41(2):78-80.
26.陈文琳,李伟等.Ti(C,N)基金属陶瓷刀具切削加工有限元模拟[J].硬质合金,2006,23(4):248-252.
27.江玉和.非金属材料化学[M].北京:科学技术文献出版社,1992
28.成云平,王淑华等.纳米材料在陶瓷刀具中的应用现状[J].超硬材料工程,2006,18(4):41-44.
29.曹同坤,邓建新.自润滑陶瓷刀具切削过程中的减摩机理研究[J].硅酸盐学报,2006,34(10):1232-1237.
30.郭旭红,芮延年,朱圣领,董桂岩.陶瓷刀具干切削等温淬火球铁(ADI)的磨损机理研究[J].摩擦学学报,2006,26(1):73-78.
31.吴少华,郭旭红.陶瓷刀具高速干切削等温淬火球铁(ADI)磨损性能研究[J].润滑与密封,2006,10:141-144.
32.石增敏,郑勇,刘文俊等.Ti(C,N)基金属陶瓷刀具的切削性能[J].中国有色金属学报,2006,16(5):805-810.
33.邓新建,艾兴,冯益华.陶瓷刀具切削加工时的磨损和润滑及其加工对象的匹配研究[J].机械工程学报,2002,38(4):40-45.,
34.Zackrisson J,Rolander U,Weinl G,et al.Microstructure of the Surface Zone in a Heat Treated Cermet Material[J].Int J Refr Met Hard Mater,1998,16:315-322.
35.钟金豹,黄传真等.纳米复相陶瓷刀具材料的研究现状[J].现代制造技术与装备,2006,4:17-21.
36 新野正之.功能梯度材料研究[J].日本复合材料学会志.1987,14(5):257.
37 洪长青,韩杰才,张幸红等.TiB_2-Cu复合材料热冲击损伤行为的数值模拟,稀有金属材料与工程.2006,1(1)
38.熊智军,赵熹华,李永强等.激光深熔焊接热源模型的研究进展[J].焊接,2006(12):12-16
39.莫立春,钱百年,国旭明等.焊接热源计算模式的研究进展[J].焊接学报,2001,22(3):93-96
40.蔡志鹏,赵海燕,鹿安理等.焊接数值模拟中分段移动热源模型的建立及应用[J].机械工程学报,2002,13(3):208-210
41.薛忠明,顾兰,张彦华.激光焊接温度场数值模拟[J].焊接学报.2003,24(2):79-82
42.曾祥呈,黄健文,张庆茂.激光焊接过程温度场的模拟[J].应用激光.2008(28):3
43.Shigreru Akiyama,Shigeyasu Amada.The thermal shock strength of Al_2O_3 by laser irradiation method.Ceramics International.2001(27):171-177
44.I.Tanishita,Heat Transfer,shoukabo press,Japan,1988,pp:155-156
45.Ceram.Soc.Japan,Mechanical properties of ceramics,Japanese Ceram.Soc,1988,PP.23-25
46.M.Itou,K.Ueda,T.sugita,Fracture mecha ics analysis of thermal shock cracking of ceramics in laser heating,J.Soc.prec.Eng.1990(58):1487-1492