粉末高温合金FGH95高速切削加工表面完整性研究
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摘要
粉末高温合金具有晶粒小、组织均匀、无宏观偏析、合金化程度高、屈服强度高及抗疲劳性能好等优点,是现代高推重比航空发动机涡轮盘等关键高温部件的首选材料。切削加工表面完整性对航空发动机零部件的疲劳寿命等服役性能起着至关重要的作用。但是目前对粉末高温合金的切削加工表面完整性的研究几乎还是空白。本文主要针对FGH95粉末高温合金的材料特性,对其切削加工特点进行研究,重点研究切削加工表面的表面粗糙度,加工硬化、残余应力、白层及表面塑性变形及其影响因素,为生产实际中控制切削参数,提高粉末高温合金零部件的服役性能提供理论和技术指导。
分析研究FGH95粉末高温合金的组织结构、相、合金中的非金属夹杂以及力学性能,为切削表面微观组织结构的转变以及表面物理力学性能的变化的研究提供基础；与GH4169高温合金的切削加工性进行对比分析,通过切削试验研究切削速度、进给量和切削深度对切削力和切削温度的影响规律；研究切削速度对切屑形貌的影响,分析其难加工特点；采用正交铣削试验获取切屑根部,研究切削过程中材料的断裂特性,探索FGH95合金切屑形成的周期性断裂机制,揭示FGH95合金切削过程的延性断裂本质,为研究其切削表面完整性奠定基础。
建立考虑切削表面弹性回复的正交铣削FGH95合金表面粗糙度模型,研究切削深度和切削速度对FGH95合金正交铣削表面粗糙度的影响规律。发现随着切削深度的增大,表面粗糙度增大。在常规切削速度范围内的表面粗糙度值明显大于高速切削得到的表面粗糙度。采用具有不同后刀面磨损量的涂层硬质合金刀片进行FGH95合金切削加工试验,揭示刀具后刀面磨损量对表面粗糙度的影响规律,确定切削加工FGH95合金时涂层硬质合金刀具的磨钝标准。
基于切削加工过程中切削力和已加工表面的应力关系建立切削加工表面硬化层深度预测模型,通过切削试验验证该模型的有效性。对FGH95切削表面的残余应力进行试验测试和有限元仿真研究,探索残余应力沿切削深度方向的分布规律。
基于切削第四变形区形成理论建立切削加工表面塑性变形计算模型,对表面塑性变形及塑性变形深度进行理论预测,在不同切削速度下进行FGH95镍基粉末高温合金切削试验和有限元仿真表面塑性剪切应变和塑性变形深度验证该理论模型的有效性。结果表明：在常规切削速度下,随着切削速度提高,已加工表面的塑性变形深度减小,塑性变形深度在0.02-0.04mm之间；已加工表面的塑性剪应变随着切削速度的提高而增大,已加工表面塑性剪应变在1.2-4.0之间。高速切削加工FGH95粉末高温合金时在其他切削用量保持不变的情况下,获得表面塑性变形深度和表面塑性剪应变较小的切削速度区间为400～2400m/min。已加工表面的塑性剪应变在沿切削深度方向上服从负指数分布,即在已加工表面上具有最大值,然后沿着垂直于已加工表面方向塑性剪应变值急剧减小。
对FGH95合金基体和已加工表面白层进行EDS能谱、XRD衍射分析研究,结果表明：FGH95合金白层与基体组织不同,白层中的强化相γ'含量比基体中增加8%-15%,且发生了γ'相的细化；FGH95合金中的Ni基固溶体在切削加工过程中发生物相变化,白层中基体相γ和强化相γ'晶格错配度增大；白层的结晶度较差且晶粒发生细化,切削速度越高,晶粒细化程度越严重,合金中的大、中型晶粒的个数不断减少,细小晶粒的个数不断增多。基于切削加工过程中切削力及切削温度和加工后表面白层厚度分析,研究切削应力、应变率和切削温度对白层厚度的影响规律,揭示FGH95合金切削加工表面白层形成的形相变耦合机制。结果表明：白层的形成与切削过程中的应力和应变率有关,随着应力和应变率的增大,白层厚度增大；切削温度的升高也导致白层厚度的增大,但是在低于材料相变临界温度时,白层仍然形成,这说明严重的塑性变形在白层形成过程中起着不可或缺的作用。
本课题得到国家重点基础研究发展计划(973)(2009CB724401)和山东省自然科学杰出青年基金(JQ200918)的支持
PM superalloy with high tensile properties has been developed for turbine disk applications in advanced turbo-engines due to its homogeneous and fine grains. Although machined surface integrity of PM superalloy has significant impacts on the parts service performance and fatigue life, there is lack of sysmatic research done in this area. Thus, the aim of this dissertation is to investigate the surface integrity in machining of PM nickel-based superalloy FGH95. In this study, the machinability of FGH95has been investigated according to its material properties. The machined surface integrity such as surface roughness, work-hardening, residual stress, white layer, surface plastic deformation and its influencing factors in the machining of FGH95are analyzed. The outputs of this research can provide theoretical base and technical guidance for the control of cutting parameters to improve the PM superalloy parts machined surafce properties in the actual production.
The investigations on the microstructure, phase, non-metallic inclusions inside the material and material mechanical properties can provide references in the machined surface microstructure and mechanical properties changes in the machining of FGH95. Contrast to the machinability of GH4169superalloy, the effects of cutting parameters on the cutting forces and cutting temperature are revealed. The effects of cutting speed on chips morphology are investigated. In order to study the chip roots fracture properties in the cutting process, the orthogonal milling experiments are carried out and SEM observation is used to analyze the chip root fracture properties. The periodical fracture mechanism in FGH95chip formation is proposed, the nature in the machining of FGH95is revealed, which lays the foundation for the study of the machined surface integrity.
Taking into account the influence of elastic recovery on machined surface, the surface roughness theoretical model in orthogonal milling of FGH95is established. The influences of depth of cut and cutting speed on the surface roughness are investigated in orthogonal milling of FGH95. The results show that the machined surface roughness increases with the increasing of depth of cut. The roughness values generated in the conventional cutting speed range are higher than roughness values generated in the high speed machining. The effects of tool flank wear on the machined surface roughness are investigated through the cutting tests. The blunt standard of coated carbide cements in the cutting of FGH95PM superalloy is proposed. The depth of work-hardening layer model is established according to the relationship of cutting forces and stress in the machined surface, the reliability of this model is verified through the cutting tests. The residual stress in the FGH95machined surface is analyzed through the cutting tests and finite element simulation, and the distribution of residual stress along the depth of cut direction is revealed.
Computational model of the machined surface plastic deformation is developed based on the the fourth deformation zone formation theory. The surface plastic deformation and its distribution are predicted by the developed computational model. The cutting tests and finite element simulation for the machining of FGH95are emloyed to verify the validity of computational model for machined surface plastic deformation. The results show that in the conventional cutting speeds, with the increasing of cutting speed the depth of machined surface plastic deformation decreased, the depth of plastic deformation is in0.02-0.04mm. However, the machined surface plastic shear strain increases with the increasing of cutting speed, the machined surface plastic shear strain is in1.2-4.0. In high speed machiing, smaller depth of machined surface plastic deformation and plastic shear strain is generated in the cutting speeds range of400-2400m/min. The machined surface plastic deformation has maximum value on the machined surface and decreases rapidly along perpendicular to the machined surface direction.
Microstrctures of white layer and bulk material have significantly differences under the EDS, XRD analysis. Strengthening phase γ' contents in white layer is higher than that in the bulk material, and the strengthening phase refinement is appeared. Ni-based solid solution phase of FGH95superalloy changes in the cutting process and the lattice mismatch of strengthening phase γ' and the matrix phase γ is increased. White layer has poor crystallinity and occurrs grain refinement, with the increasing of cutting speed, the grain refinement is more serious. With the increasing of cutting speed, the number of large-sized and medium-sized grains continus to reduce but the number of small-sized grains increases. The deformation phase transformation mechanism in PM superalloy machined surface white layer formation is explored. The effects of cutting speed and tool flank wear on FGH95machined surface white layer thickness are investigated. The influences of cutting stress, strain rate and cutting temperature on white layer thickness are analyzed. The results show that with the increase of cutting stress and strain rate, white layer thickness increases. The increasing of cutting temperature also induces to increase of white layer thickness, but white layer is still formed when the cutting temperature is lower than material phase transition temperature, which indicates that severe plastic deformation plays an integral role in the formation of white layer.
This work is sponsored by National Basic Research Program of China (973)(2009CB724401) and Foundation of Shandong Province of China for Distinguished Young Scholars (JQ200918) for financial supports.
分析研究FGH95粉末高温合金的组织结构、相、合金中的非金属夹杂以及力学性能,为切削表面微观组织结构的转变以及表面物理力学性能的变化的研究提供基础；与GH4169高温合金的切削加工性进行对比分析,通过切削试验研究切削速度、进给量和切削深度对切削力和切削温度的影响规律；研究切削速度对切屑形貌的影响,分析其难加工特点；采用正交铣削试验获取切屑根部,研究切削过程中材料的断裂特性,探索FGH95合金切屑形成的周期性断裂机制,揭示FGH95合金切削过程的延性断裂本质,为研究其切削表面完整性奠定基础。
建立考虑切削表面弹性回复的正交铣削FGH95合金表面粗糙度模型,研究切削深度和切削速度对FGH95合金正交铣削表面粗糙度的影响规律。发现随着切削深度的增大,表面粗糙度增大。在常规切削速度范围内的表面粗糙度值明显大于高速切削得到的表面粗糙度。采用具有不同后刀面磨损量的涂层硬质合金刀片进行FGH95合金切削加工试验,揭示刀具后刀面磨损量对表面粗糙度的影响规律,确定切削加工FGH95合金时涂层硬质合金刀具的磨钝标准。
基于切削加工过程中切削力和已加工表面的应力关系建立切削加工表面硬化层深度预测模型,通过切削试验验证该模型的有效性。对FGH95切削表面的残余应力进行试验测试和有限元仿真研究,探索残余应力沿切削深度方向的分布规律。
基于切削第四变形区形成理论建立切削加工表面塑性变形计算模型,对表面塑性变形及塑性变形深度进行理论预测,在不同切削速度下进行FGH95镍基粉末高温合金切削试验和有限元仿真表面塑性剪切应变和塑性变形深度验证该理论模型的有效性。结果表明：在常规切削速度下,随着切削速度提高,已加工表面的塑性变形深度减小,塑性变形深度在0.02-0.04mm之间；已加工表面的塑性剪应变随着切削速度的提高而增大,已加工表面塑性剪应变在1.2-4.0之间。高速切削加工FGH95粉末高温合金时在其他切削用量保持不变的情况下,获得表面塑性变形深度和表面塑性剪应变较小的切削速度区间为400～2400m/min。已加工表面的塑性剪应变在沿切削深度方向上服从负指数分布,即在已加工表面上具有最大值,然后沿着垂直于已加工表面方向塑性剪应变值急剧减小。
对FGH95合金基体和已加工表面白层进行EDS能谱、XRD衍射分析研究,结果表明：FGH95合金白层与基体组织不同,白层中的强化相γ'含量比基体中增加8%-15%,且发生了γ'相的细化；FGH95合金中的Ni基固溶体在切削加工过程中发生物相变化,白层中基体相γ和强化相γ'晶格错配度增大；白层的结晶度较差且晶粒发生细化,切削速度越高,晶粒细化程度越严重,合金中的大、中型晶粒的个数不断减少,细小晶粒的个数不断增多。基于切削加工过程中切削力及切削温度和加工后表面白层厚度分析,研究切削应力、应变率和切削温度对白层厚度的影响规律,揭示FGH95合金切削加工表面白层形成的形相变耦合机制。结果表明：白层的形成与切削过程中的应力和应变率有关,随着应力和应变率的增大,白层厚度增大；切削温度的升高也导致白层厚度的增大,但是在低于材料相变临界温度时,白层仍然形成,这说明严重的塑性变形在白层形成过程中起着不可或缺的作用。
本课题得到国家重点基础研究发展计划(973)(2009CB724401)和山东省自然科学杰出青年基金(JQ200918)的支持
PM superalloy with high tensile properties has been developed for turbine disk applications in advanced turbo-engines due to its homogeneous and fine grains. Although machined surface integrity of PM superalloy has significant impacts on the parts service performance and fatigue life, there is lack of sysmatic research done in this area. Thus, the aim of this dissertation is to investigate the surface integrity in machining of PM nickel-based superalloy FGH95. In this study, the machinability of FGH95has been investigated according to its material properties. The machined surface integrity such as surface roughness, work-hardening, residual stress, white layer, surface plastic deformation and its influencing factors in the machining of FGH95are analyzed. The outputs of this research can provide theoretical base and technical guidance for the control of cutting parameters to improve the PM superalloy parts machined surafce properties in the actual production.
The investigations on the microstructure, phase, non-metallic inclusions inside the material and material mechanical properties can provide references in the machined surface microstructure and mechanical properties changes in the machining of FGH95. Contrast to the machinability of GH4169superalloy, the effects of cutting parameters on the cutting forces and cutting temperature are revealed. The effects of cutting speed on chips morphology are investigated. In order to study the chip roots fracture properties in the cutting process, the orthogonal milling experiments are carried out and SEM observation is used to analyze the chip root fracture properties. The periodical fracture mechanism in FGH95chip formation is proposed, the nature in the machining of FGH95is revealed, which lays the foundation for the study of the machined surface integrity.
Taking into account the influence of elastic recovery on machined surface, the surface roughness theoretical model in orthogonal milling of FGH95is established. The influences of depth of cut and cutting speed on the surface roughness are investigated in orthogonal milling of FGH95. The results show that the machined surface roughness increases with the increasing of depth of cut. The roughness values generated in the conventional cutting speed range are higher than roughness values generated in the high speed machining. The effects of tool flank wear on the machined surface roughness are investigated through the cutting tests. The blunt standard of coated carbide cements in the cutting of FGH95PM superalloy is proposed. The depth of work-hardening layer model is established according to the relationship of cutting forces and stress in the machined surface, the reliability of this model is verified through the cutting tests. The residual stress in the FGH95machined surface is analyzed through the cutting tests and finite element simulation, and the distribution of residual stress along the depth of cut direction is revealed.
Computational model of the machined surface plastic deformation is developed based on the the fourth deformation zone formation theory. The surface plastic deformation and its distribution are predicted by the developed computational model. The cutting tests and finite element simulation for the machining of FGH95are emloyed to verify the validity of computational model for machined surface plastic deformation. The results show that in the conventional cutting speeds, with the increasing of cutting speed the depth of machined surface plastic deformation decreased, the depth of plastic deformation is in0.02-0.04mm. However, the machined surface plastic shear strain increases with the increasing of cutting speed, the machined surface plastic shear strain is in1.2-4.0. In high speed machiing, smaller depth of machined surface plastic deformation and plastic shear strain is generated in the cutting speeds range of400-2400m/min. The machined surface plastic deformation has maximum value on the machined surface and decreases rapidly along perpendicular to the machined surface direction.
Microstrctures of white layer and bulk material have significantly differences under the EDS, XRD analysis. Strengthening phase γ' contents in white layer is higher than that in the bulk material, and the strengthening phase refinement is appeared. Ni-based solid solution phase of FGH95superalloy changes in the cutting process and the lattice mismatch of strengthening phase γ' and the matrix phase γ is increased. White layer has poor crystallinity and occurrs grain refinement, with the increasing of cutting speed, the grain refinement is more serious. With the increasing of cutting speed, the number of large-sized and medium-sized grains continus to reduce but the number of small-sized grains increases. The deformation phase transformation mechanism in PM superalloy machined surface white layer formation is explored. The effects of cutting speed and tool flank wear on FGH95machined surface white layer thickness are investigated. The influences of cutting stress, strain rate and cutting temperature on white layer thickness are analyzed. The results show that with the increase of cutting stress and strain rate, white layer thickness increases. The increasing of cutting temperature also induces to increase of white layer thickness, but white layer is still formed when the cutting temperature is lower than material phase transition temperature, which indicates that severe plastic deformation plays an integral role in the formation of white layer.
This work is sponsored by National Basic Research Program of China (973)(2009CB724401) and Foundation of Shandong Province of China for Distinguished Young Scholars (JQ200918) for financial supports.
引文
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