纳米硬质合金刀具材料的ELID磨削机理及其切削性能研究
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摘要
纳米硬质合金具有比普通硬质合金更高的硬度、强度及韧性,在需要高耐磨性及强度的模具、工具、切削刀具(如微小刀具)等领域具有广泛的应用前景。目前关于纳米硬质合金的研究热点主要集中于纳米粉体制备技术、喷涂技术、纳米块体烧结技术以及和应用有关的材料摩擦磨损性能、刀具切削性能研究等方面,而对纳米硬质合金材料实用化需要解决的精密加工机理及工艺技术的研究相对较少。因此,研究纳米硬质合金的精密加工技术,对促进纳米硬质合金材料的实用化、扩大其应用范围具有十分重要的意义。
在线电解修整(Electrolytic In-process Dressing, ELID)磨削技术是近年发展起来的一种新的超精密磨削技术,利用在线电解技术在砂轮表面形成氧化膜,从而实现砂轮在线修整。其中,砂轮表面氧化膜的性能对磨削过程及磨削表面质量有至关重要的影响。ELID磨削技术适于硬脆材料等难加工材料的精密磨削,用ELID磨削技术磨削硬质合金取得了很好效果,因此,本文应用ELID磨削技术来进行纳米硬质合金精密磨削技术的研究。
本文在分析ELID磨削技术国内外研究进展的基础上,研究了ELID磨削砂轮表面氧化膜厚度、磨粒接触刚度计算模型,并进一步研究了纳米硬质合金ELID磨削机理;在综述纳米硬质合金材料及加工技术国内外研究进展的基础上,研究了纳米硬质合金刀具摩擦磨损性能及其切削性能。
第一,对ELID磨削砂轮表面氧化膜厚度、磨粒接触刚度进行了系统研究。建立了脉冲电解条件下氧化膜厚度计算模型,并进行了仿真与实验验证,从脉冲电解能力这一新角度揭示了ELID磨削砂轮非线性电解的原因;建立了氧化膜中磨粒接触刚度计算模型并进行了仿真分析与实验验证,模型反映了氧化膜中磨粒接触刚度随磨削条件的变化,揭示了ELID磨削砂轮氧化膜自适应磨削过程的规律。
第二,在氧化膜性能研究基础上,基于最小切削厚度理论研究了纳米硬质合金ELID磨削表面微观形貌形成机理。对最小切削厚度进行了理论分析与仿真,研究了ELID磨削锋锐磨粒微切削机理及钝化磨粒的挤压机理,并进行了仿真与实验验证;研究了纳米硬质合金的ELID磨削机理,由于纳米硬质合金硬度较高,磨削力较大,砂轮氧化膜弹性变形较大,从而实际磨削深度减小,同时由于由于氧化膜刚度的影响,氧化膜包含钝化磨粒,产生纳米挤压作用,使得纳米硬质合金ELID磨削后表面粗糙度较好。
第三,研究了纳米硬质合金材料的摩擦磨损性能。首先利用球盘式摩擦磨损试验机研究了纳米硬质合金的摩擦系数、耐磨损性,然后利用SEM观察了磨损表面,研究了磨损机理。研究表明,随晶粒度减小,纳米硬质合金摩擦系数有降低的趋势;纳米硬质合金耐磨性随钴含量增加而降低,随钴含量不同,磨损机理显著不同,WC-7Co表现为晶粒脱落,WC-10Co表现为塑性流动。
第四,应用ELID磨削技术,制备新型纳米硬质合金刀具,并从刀具锋锐度、刀具磨损速率等几个角度对其切削性能进行了综合评价。首先利用ELID磨削技术对切削刃口进行了精密磨削,利用原子力显微镜(AFM)对刃口半径进行了研究;然后利用所研制的纳米硬质合金刀具对白口铸铁、铝基复合材料进行了切削试验,实测了刀具磨损速率,并建立了刀具磨损速率计算模型,对模型进行了初步的仿真与实验分析。研究表明,建立的刀具磨损速率模型预测的后刀面磨损宽度与实验结果相符,表明此模型在实验范围内可以较准确的预测后刀面磨损宽度。
Nano cemented carbide is superior to common cemented carbide in properties, such as high hardness, toughness and strength. Nano cemented carbide has wide use in places such as some hard-wearing die, tool and cutter (for example: microtool), etc. Research focus of the nano cemented carbide is concentrated on preparing technology of nanometer powder, spraying technology, sintering technology and friction and wear per-formance, and cutting performance etc., but research of ultraprecision processing mechanism and technology of the nano cemented carbide is relatively less. So, explore ultraprecision processing technology and mechanism of the nano cemented carbide, to turn the nano cemented car-bide into application, and to expand their application fields have impor-tant significance.
ELID (Electrolytic In-process Dressing) grinding technology is new technology of ultraprecision grinding, that is developed for the past few years. The oxide film is formed on grinding wheel by electrolytic in-process technology, thus the wheel is in-process dressed. Performances of the oxide film of wheel surface on grinding process and grinding sur-face quality have important influence. It’s good for grinding difficult to machine materials as hard and brittle materials etc. To obtain good results grinding cemented carbide by ELID grinding technology. So, prepare grinding nano cemented carbide by ELID grinding technology.
In this paper on the basis of research progress in country and oversea for ELID grinding technology, the thickness, contact stiffness of the oxide film on wheel surface in ELID grinding are systematic researched. Fur-ther ELID grinding mechanisms for nano cemented carbide are researched. On the basis of research progress in country and oversea for nano ce-mented carbide and its processing technology, the friction and wear per-formances and cutting capability are researched.
First, the thickness, and contact stiffness of the oxide film on wheel surface in ELID grinding is systematic researched. When the wheel is electrolyzed by pulse power, set up calculate model of the oxide film thickness and go on theoretical simulation and experimental researches, from the pulse electrolysis capacity this new angle the non-linear elec-trolytic reason in ELID grinding is announced. Set up calculate model of the oxide film contact stiffness and go on simulation and experimental analysis, the characteristic, that oxide film contact stiffness with grinding changing is reflected, self-adapting law of the oxide film in ELID grind-ing has showed.
Second, from the performances of the oxide film, base on the theory of minimum thickness of cut (MTC) the surface micro topography for-mation mechanisms of nano cemented carbide in ELID grinding are re-searched. MTC is theoretically analyzed and simulated, and microcutting mechanism of sharp grits and burnishing mechanism of passivating grits is theoretically analyzed, simulated and experimentally researched a little. ELID grinding mechanisms of nano cemented carbide are studied, because the hardness is relatively high, and grinding forces are relatively great, make oxide film larger elastic deformation, and actual depth of cut (ADOC) of a grinding wheel is small. At the same time, because the effect of stiffness coefficient of the oxide film, the nano-burnished of the pas-sivating grits included in the oxide film makes ELID grinding surface quality of the nano cemented carbide better.
Third, friction and wear performance of nano cemented carbide is experimentally researched. The coefficient of friction and hard-wearing of nano cemented carbide are studied by ball-on-disk friction and wear tester, the worn surface is observed by SEM, and the wear mechanism is studied. Results have suggested, as the crystalline grain degree is reduced, the coefficient of friction of nano cemented carbide has the tendency to reduce, and the wearability of nano cemented carbide is reduced with the cobalt contents increase. The cobalt content of nano cemented carbide is different, the wear mechanisms are prominent and different, the WC-7Co shows the crystalline grains come off, the WC-10Co shows the plastic flow.
Fourth, based on ELID grinding technology new style nano-cutters are manufactured and its cutting performances are generally researched from the sharpness and wear rate of cutter. The blade is accurately ground by ELID grinding technology, and the edge radius on blade is researched by AFM. The white cast iron and aluminium base composite material is cut by nano cemented carbide cutter; the cutter wear rate is measured, set up cutter wear rate model, and carried on preliminary simulation and experimental analysis. Results have showed, good agreements between the predicted and measured tool flank wear land width show the devel-oped tool wear model can accurately predict tool flank wear to some ex-tent.
在线电解修整(Electrolytic In-process Dressing, ELID)磨削技术是近年发展起来的一种新的超精密磨削技术,利用在线电解技术在砂轮表面形成氧化膜,从而实现砂轮在线修整。其中,砂轮表面氧化膜的性能对磨削过程及磨削表面质量有至关重要的影响。ELID磨削技术适于硬脆材料等难加工材料的精密磨削,用ELID磨削技术磨削硬质合金取得了很好效果,因此,本文应用ELID磨削技术来进行纳米硬质合金精密磨削技术的研究。
本文在分析ELID磨削技术国内外研究进展的基础上,研究了ELID磨削砂轮表面氧化膜厚度、磨粒接触刚度计算模型,并进一步研究了纳米硬质合金ELID磨削机理;在综述纳米硬质合金材料及加工技术国内外研究进展的基础上,研究了纳米硬质合金刀具摩擦磨损性能及其切削性能。
第一,对ELID磨削砂轮表面氧化膜厚度、磨粒接触刚度进行了系统研究。建立了脉冲电解条件下氧化膜厚度计算模型,并进行了仿真与实验验证,从脉冲电解能力这一新角度揭示了ELID磨削砂轮非线性电解的原因;建立了氧化膜中磨粒接触刚度计算模型并进行了仿真分析与实验验证,模型反映了氧化膜中磨粒接触刚度随磨削条件的变化,揭示了ELID磨削砂轮氧化膜自适应磨削过程的规律。
第二,在氧化膜性能研究基础上,基于最小切削厚度理论研究了纳米硬质合金ELID磨削表面微观形貌形成机理。对最小切削厚度进行了理论分析与仿真,研究了ELID磨削锋锐磨粒微切削机理及钝化磨粒的挤压机理,并进行了仿真与实验验证;研究了纳米硬质合金的ELID磨削机理,由于纳米硬质合金硬度较高,磨削力较大,砂轮氧化膜弹性变形较大,从而实际磨削深度减小,同时由于由于氧化膜刚度的影响,氧化膜包含钝化磨粒,产生纳米挤压作用,使得纳米硬质合金ELID磨削后表面粗糙度较好。
第三,研究了纳米硬质合金材料的摩擦磨损性能。首先利用球盘式摩擦磨损试验机研究了纳米硬质合金的摩擦系数、耐磨损性,然后利用SEM观察了磨损表面,研究了磨损机理。研究表明,随晶粒度减小,纳米硬质合金摩擦系数有降低的趋势;纳米硬质合金耐磨性随钴含量增加而降低,随钴含量不同,磨损机理显著不同,WC-7Co表现为晶粒脱落,WC-10Co表现为塑性流动。
第四,应用ELID磨削技术,制备新型纳米硬质合金刀具,并从刀具锋锐度、刀具磨损速率等几个角度对其切削性能进行了综合评价。首先利用ELID磨削技术对切削刃口进行了精密磨削,利用原子力显微镜(AFM)对刃口半径进行了研究;然后利用所研制的纳米硬质合金刀具对白口铸铁、铝基复合材料进行了切削试验,实测了刀具磨损速率,并建立了刀具磨损速率计算模型,对模型进行了初步的仿真与实验分析。研究表明,建立的刀具磨损速率模型预测的后刀面磨损宽度与实验结果相符,表明此模型在实验范围内可以较准确的预测后刀面磨损宽度。
Nano cemented carbide is superior to common cemented carbide in properties, such as high hardness, toughness and strength. Nano cemented carbide has wide use in places such as some hard-wearing die, tool and cutter (for example: microtool), etc. Research focus of the nano cemented carbide is concentrated on preparing technology of nanometer powder, spraying technology, sintering technology and friction and wear per-formance, and cutting performance etc., but research of ultraprecision processing mechanism and technology of the nano cemented carbide is relatively less. So, explore ultraprecision processing technology and mechanism of the nano cemented carbide, to turn the nano cemented car-bide into application, and to expand their application fields have impor-tant significance.
ELID (Electrolytic In-process Dressing) grinding technology is new technology of ultraprecision grinding, that is developed for the past few years. The oxide film is formed on grinding wheel by electrolytic in-process technology, thus the wheel is in-process dressed. Performances of the oxide film of wheel surface on grinding process and grinding sur-face quality have important influence. It’s good for grinding difficult to machine materials as hard and brittle materials etc. To obtain good results grinding cemented carbide by ELID grinding technology. So, prepare grinding nano cemented carbide by ELID grinding technology.
In this paper on the basis of research progress in country and oversea for ELID grinding technology, the thickness, contact stiffness of the oxide film on wheel surface in ELID grinding are systematic researched. Fur-ther ELID grinding mechanisms for nano cemented carbide are researched. On the basis of research progress in country and oversea for nano ce-mented carbide and its processing technology, the friction and wear per-formances and cutting capability are researched.
First, the thickness, and contact stiffness of the oxide film on wheel surface in ELID grinding is systematic researched. When the wheel is electrolyzed by pulse power, set up calculate model of the oxide film thickness and go on theoretical simulation and experimental researches, from the pulse electrolysis capacity this new angle the non-linear elec-trolytic reason in ELID grinding is announced. Set up calculate model of the oxide film contact stiffness and go on simulation and experimental analysis, the characteristic, that oxide film contact stiffness with grinding changing is reflected, self-adapting law of the oxide film in ELID grind-ing has showed.
Second, from the performances of the oxide film, base on the theory of minimum thickness of cut (MTC) the surface micro topography for-mation mechanisms of nano cemented carbide in ELID grinding are re-searched. MTC is theoretically analyzed and simulated, and microcutting mechanism of sharp grits and burnishing mechanism of passivating grits is theoretically analyzed, simulated and experimentally researched a little. ELID grinding mechanisms of nano cemented carbide are studied, because the hardness is relatively high, and grinding forces are relatively great, make oxide film larger elastic deformation, and actual depth of cut (ADOC) of a grinding wheel is small. At the same time, because the effect of stiffness coefficient of the oxide film, the nano-burnished of the pas-sivating grits included in the oxide film makes ELID grinding surface quality of the nano cemented carbide better.
Third, friction and wear performance of nano cemented carbide is experimentally researched. The coefficient of friction and hard-wearing of nano cemented carbide are studied by ball-on-disk friction and wear tester, the worn surface is observed by SEM, and the wear mechanism is studied. Results have suggested, as the crystalline grain degree is reduced, the coefficient of friction of nano cemented carbide has the tendency to reduce, and the wearability of nano cemented carbide is reduced with the cobalt contents increase. The cobalt content of nano cemented carbide is different, the wear mechanisms are prominent and different, the WC-7Co shows the crystalline grains come off, the WC-10Co shows the plastic flow.
Fourth, based on ELID grinding technology new style nano-cutters are manufactured and its cutting performances are generally researched from the sharpness and wear rate of cutter. The blade is accurately ground by ELID grinding technology, and the edge radius on blade is researched by AFM. The white cast iron and aluminium base composite material is cut by nano cemented carbide cutter; the cutter wear rate is measured, set up cutter wear rate model, and carried on preliminary simulation and experimental analysis. Results have showed, good agreements between the predicted and measured tool flank wear land width show the devel-oped tool wear model can accurately predict tool flank wear to some ex-tent.
引文
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