切削GH4169的相关机理及高效切削技术的基础研究
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摘要
镍基高温合金GH4169因具有优良的热强性能、热稳定性能和热疲劳性能，常用于制造航空发动机与燃气轮机的轮盘、叶片等耐热零部件。随着国内电力行业的蓬勃发展，大型电站的相继建立，汽轮机需求不断增加。但由于GH4169切削加工性很差，主要表现为切屑的形成、切削力、切削温度、刀具磨损与破损等都呈现特有的规律，切削加工效率低，严重制约其广泛应用，GH4169的高效切削是制造业急需解决的问题。因此，研究切削GH4169的相关机理及高效切削技术具有重要的理论意义和广阔的应用价值。
通过提取切屑根深入研究锯齿形切屑形成的物理过程，结合积屑瘤对切屑形成的影响，揭示GH4169的切削变形机理，提出锯齿屑形成的过程包括初级、过渡和最后三个阶段，在切削程中，剪切角不断减小、剪切面转变为“剪切体”，断裂和绝热剪切共同作用而产生锯齿形切屑。并基于锯齿屑的几何特征建立剪切带变形的计算模型；最后研究了切削参数对锯齿形切屑几何特征的影响规律。
从涂层材料、切削力、切削温度、刀具几何角度及刀具使用寿命等方面，通过切削试验和仿真分析优选适用高效切削GH4169的刀片涂层材料和合理刀具前角。通过对刀具磨损形态及其特征的观测，分析刀具材料从刀具基体脱落的物理过程，揭示切削GH4169刀具磨损机理。PVD涂层硬质合金刀具在低速时易形成积屑瘤，造成崩刃；当切削速度提高时，刀具基体形成片层状磨损碎片的脱落，是造成刀具磨损的主要形式；刀-屑/工件间的扩散与氧化，增加了磨损碎片形成的密度，加速了刀具磨损。最后依据切削原理和摩擦磨损学给出了刀具磨损的物理过程模型。
在刀具磨损机理研究基础上，考虑粘结、扩散和氧化磨损均是滑动磨损的特征，应用滑动磨损的剥层理论，以分析靠近表面的金属材料的塑性变形和断裂行为为基础，并结合刀具材料在切削过程中的力学性能变化，建立并验证硬质合金刀具切削GH4169的后刀面磨损模型。
针对每一对刀具-工件组合在切削加工过程中存在最佳的切削温度，使得刀具-工件具有最大的强度比，根据所建刀具磨损模型，对最佳切削温度进行求解，以保证刀具达到磨钝标准时，切削长度最长；并通过切削试验验证所求最佳切削温度的正确性；基于最小二乘法建立使切削过程在最佳切削温度下进行的切削参数经验模型，提出一种恒温切削的方法，为切削用量的合理选择提供一种有效而快速的手段；最后采用表面粗糙度评价恒温切削技术的可行性，结果表明，恒温切削技术有助于合理选择切削用量，减小表面粗糙度值，提高切削加工效率，符合高效切削技术的发展趋势。
Nickel-base superalloy GH4169is commonly used to produce aerospace engines andgas turbine wheel, blades and other heat-resistant parts, due to its high strength, highstability and anti-fatigue properties at high temperature. With the rapid development ofthe domestic power industry, large-scale power stations have been established, and thedemand of gas turbine is increasing. However, the poor machinability of GH4169,which is represented by the special law in chip formation, cutting force, cuttingtemperature and tool wear in machining GH4169, leads to low cutting efficiency andrestricting its wide application severely. The high-efficiency cutting technology ofNickel-base superalloy GH4169is one of the urgent problems in today's manufacturing.Therefore, the research on high-efficiency cutting technology of GH4169and its relatedmechanism have theoretical significance and wide application value.
The chip formation process was studied by getting chip root. With the researches ofthe formation of built-up-edge (BUE) and its effects on chip formation, the cuttingdeformation mechanism was studied. The opinion that serrated chip formation processincludes three stages (primary, transition, and the last stage) was proposed. In thecutting process, the shear plane changed into ‘shear body’ with the decreasing of theshear angle. The serrated chip generated under the combined action of fracture andadiabatic shear. The model involving deformation of shear band based on the geometrycharacteristic of serrated chip was established. The effects of cutting parameters on thegeometry characteristic of serrated chip were also studied at last.
The TiAlN coating and favorable tool geometry were chosen through cuttingexperiments and FEM in terms of tool material, cutting force, cutting temperature, toolgeometry and tool life. The physic process of tool material peeling off from toolsubstrate was studied though observing tool wear morphology and its features analysis,and the tool wear mechanism in machining GH4169was revealed. In machiningGH4169using PVD-film carbide tool, the BUE easily generated at low cutting speedand its falling off causes tool chipping. When cutting speed increased, tool substratematerial peeled off in the form of lamellar wear debris. This is the main form leading totool wear. The diffusion and oxidation between tool and chip/workpiece made thedensity of wear debris increase and then accelerating tool wear. The model representingtool wear process was established in the light of cutting theory and friction wear theory.
Based on the research of tool wear mechanism, the adhesion, diffusion and oxidationwear is considered as the characteristics of slide wear. The delamination theory ofsliding wear was used to analyze the plastic deformation and fracture behavior of metallic materials which is closed to the tool surface. Tool flank wear model wasestablished considering the mechanical property changes of tool material, and the wearmodel was verified through experiments.
For each pair of the tool-workpiece, there exists an optimal cutting temperature tomake the strength ratio of tool-workpiece material maximum in cutting process. Theoptimal cutting temperature was calculated in the light of the established wear model, inorder to make the cutting length longest when tool fail. Excellent experimentalagreement was achieved in optimal temperature calculated by the established model.The empirical model using cutting parameters at the optimal cutting temperature wasestablished using the least squares method. The thermostatic cutting method wasproposed to provide an effective and rapid method for the reasonable choice cuttingparameters. Finally, the surface roughness was used to evaluate the feasibility ofthermostatic cutting technology. The results show that thermostatic cutting technologyhelps to select the cutting parameters, reduce the surface roughness value and improvecutting efficiency, in accordance with the development trends of high-efficiency cuttingtechnology.
通过提取切屑根深入研究锯齿形切屑形成的物理过程，结合积屑瘤对切屑形成的影响，揭示GH4169的切削变形机理，提出锯齿屑形成的过程包括初级、过渡和最后三个阶段，在切削程中，剪切角不断减小、剪切面转变为“剪切体”，断裂和绝热剪切共同作用而产生锯齿形切屑。并基于锯齿屑的几何特征建立剪切带变形的计算模型；最后研究了切削参数对锯齿形切屑几何特征的影响规律。
从涂层材料、切削力、切削温度、刀具几何角度及刀具使用寿命等方面，通过切削试验和仿真分析优选适用高效切削GH4169的刀片涂层材料和合理刀具前角。通过对刀具磨损形态及其特征的观测，分析刀具材料从刀具基体脱落的物理过程，揭示切削GH4169刀具磨损机理。PVD涂层硬质合金刀具在低速时易形成积屑瘤，造成崩刃；当切削速度提高时，刀具基体形成片层状磨损碎片的脱落，是造成刀具磨损的主要形式；刀-屑/工件间的扩散与氧化，增加了磨损碎片形成的密度，加速了刀具磨损。最后依据切削原理和摩擦磨损学给出了刀具磨损的物理过程模型。
在刀具磨损机理研究基础上，考虑粘结、扩散和氧化磨损均是滑动磨损的特征，应用滑动磨损的剥层理论，以分析靠近表面的金属材料的塑性变形和断裂行为为基础，并结合刀具材料在切削过程中的力学性能变化，建立并验证硬质合金刀具切削GH4169的后刀面磨损模型。
针对每一对刀具-工件组合在切削加工过程中存在最佳的切削温度，使得刀具-工件具有最大的强度比，根据所建刀具磨损模型，对最佳切削温度进行求解，以保证刀具达到磨钝标准时，切削长度最长；并通过切削试验验证所求最佳切削温度的正确性；基于最小二乘法建立使切削过程在最佳切削温度下进行的切削参数经验模型，提出一种恒温切削的方法，为切削用量的合理选择提供一种有效而快速的手段；最后采用表面粗糙度评价恒温切削技术的可行性，结果表明，恒温切削技术有助于合理选择切削用量，减小表面粗糙度值，提高切削加工效率，符合高效切削技术的发展趋势。
Nickel-base superalloy GH4169is commonly used to produce aerospace engines andgas turbine wheel, blades and other heat-resistant parts, due to its high strength, highstability and anti-fatigue properties at high temperature. With the rapid development ofthe domestic power industry, large-scale power stations have been established, and thedemand of gas turbine is increasing. However, the poor machinability of GH4169,which is represented by the special law in chip formation, cutting force, cuttingtemperature and tool wear in machining GH4169, leads to low cutting efficiency andrestricting its wide application severely. The high-efficiency cutting technology ofNickel-base superalloy GH4169is one of the urgent problems in today's manufacturing.Therefore, the research on high-efficiency cutting technology of GH4169and its relatedmechanism have theoretical significance and wide application value.
The chip formation process was studied by getting chip root. With the researches ofthe formation of built-up-edge (BUE) and its effects on chip formation, the cuttingdeformation mechanism was studied. The opinion that serrated chip formation processincludes three stages (primary, transition, and the last stage) was proposed. In thecutting process, the shear plane changed into ‘shear body’ with the decreasing of theshear angle. The serrated chip generated under the combined action of fracture andadiabatic shear. The model involving deformation of shear band based on the geometrycharacteristic of serrated chip was established. The effects of cutting parameters on thegeometry characteristic of serrated chip were also studied at last.
The TiAlN coating and favorable tool geometry were chosen through cuttingexperiments and FEM in terms of tool material, cutting force, cutting temperature, toolgeometry and tool life. The physic process of tool material peeling off from toolsubstrate was studied though observing tool wear morphology and its features analysis,and the tool wear mechanism in machining GH4169was revealed. In machiningGH4169using PVD-film carbide tool, the BUE easily generated at low cutting speedand its falling off causes tool chipping. When cutting speed increased, tool substratematerial peeled off in the form of lamellar wear debris. This is the main form leading totool wear. The diffusion and oxidation between tool and chip/workpiece made thedensity of wear debris increase and then accelerating tool wear. The model representingtool wear process was established in the light of cutting theory and friction wear theory.
Based on the research of tool wear mechanism, the adhesion, diffusion and oxidationwear is considered as the characteristics of slide wear. The delamination theory ofsliding wear was used to analyze the plastic deformation and fracture behavior of metallic materials which is closed to the tool surface. Tool flank wear model wasestablished considering the mechanical property changes of tool material, and the wearmodel was verified through experiments.
For each pair of the tool-workpiece, there exists an optimal cutting temperature tomake the strength ratio of tool-workpiece material maximum in cutting process. Theoptimal cutting temperature was calculated in the light of the established wear model, inorder to make the cutting length longest when tool fail. Excellent experimentalagreement was achieved in optimal temperature calculated by the established model.The empirical model using cutting parameters at the optimal cutting temperature wasestablished using the least squares method. The thermostatic cutting method wasproposed to provide an effective and rapid method for the reasonable choice cuttingparameters. Finally, the surface roughness was used to evaluate the feasibility ofthermostatic cutting technology. The results show that thermostatic cutting technologyhelps to select the cutting parameters, reduce the surface roughness value and improvecutting efficiency, in accordance with the development trends of high-efficiency cuttingtechnology.
引文
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