铣削Ti6Al4V刀具刃口钝化研究
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摘要
钛合金Ti6Al4V具有比强度高、耐热性和耐蚀性好等优良性能,被广泛应用于航空航天工业,然而由于其导热系数低、化学活性高、弹性模量小等特点使其成为典型的难加工材料。在铣削Ti6Al4V过程中,由于Ti6Al4V材料的导热系数低,而且切屑与前刀面的接触长度极短,切削时产生的热不易传出,集中在切削变形区和切削刃附近的较小范围内,切削刃刃口处会产生极高的切削温度,而且铣削时切削刃所受到的负载是不连续的,从而导致刀具刃口快速磨损破损。刀具刃口钝化结构成为保证刀具寿命、提高加工效率的一个十分重要的因素。
本文以铣削Ti6Al4V刀具切削刃刃口钝化结构为研究对象,通过有限元仿真方法,以最低切削温度为优化指标,对适合铣削Ti6Al4V刀具的刃口钝化结构进行了优化；并通过铣削Ti6Al4V过程中切削力、切削温度、切屑形貌、刀具寿命、表面质量完整性分析,研究了不同刃口钝化结构对铣削Ti6Al4V加工过程的影响。
1.基于Power-Law模型建立Ti6Al4V的本构关系模型,并对三维铣削过程进行了二维简化,建立了能够反映刃口特点的刀片模型,并通过仿真切削力与实验结果的对比,验证了有限元模型的正确性。
2.通过切削力、切削温度的对比,研究了不同刃口钝圆半径及不同刃口复合结构对铣削Ti6Al4V的影响规律,并以最低切削温度为优化指标,对适合铣削Ti6Al4V的刃口钝圆半径及刃口复合结构进行了优化。
3.通过不同刃口钝圆半径的刀具铣削Ti6Al4V的刀具寿命试验研究,发现在相同切削条件下,当切削路程相同时,不同钝圆半径的刀具磨损速度是不同的,切削力的大小也是不同的。
4.通过刃口钝化型式为钝圆刃的刀具与刃口未钝化刀具铣削Ti6Al4V试验,揭示刃口钝化刀具对于铣削Ti6Al4V表面质量完整性的影响规律及作用机理。
Ti6A14V are extensively used in aerospace industry because of their excellent properties of high specific strength (strength-to-weight ratio), fracture resistant characteristics, and their exceptional resistance to corrosion. However, Ti6A14V are considered as typical difficult-to-cut materials due to their high temperature strength, high chemical reactivity and its low modulus of elasticity. During milling Ti6A14V, as a result of low conductivity and short contact length between chip and rake face, the cutting heat can not diffuse easily and only concentrate around the deformation area and the cutting edge. Thus, the temperature of the cutting edge should be very high. What's more, the load on the cutting edge is discontinuous as milling Ti6A14V, so the cutting edge could be easily worn. Cutting tool's structure, especially its tool edge preparation, becomes one of the key factors that influence the tool life and improve machining efficiency. In this paper, some researches were carried out on the tool edge preparation by FEM analysis and the edge preparation size for milling Ti6A14V was optimized aimed at the lowest cutting temperature. The influence of different edge preparation on milling Ti6A14V was investigated by analysis the cutting force, cutting temperature, chip geometries, tool life and surface quality integrity.
1. The constitutive material model of Ti6A14V was built based on Power-Law.3D milling process was simplified into 2D and the model of insert was also built to reflect the characteristics of the cutting edge. At last, the FEM model was verified to be accurate due to FEM cutting forces and experiment forces.
2. By comparison of cutting force and cutting temperature, the influences of different edge radius and edge composite structures on milling Ti6A14V were investigated. Aimed at the lowest cutting temperature, edge radius and edge composite structure were optimized for milling Ti6A14V.
3. In the experiment about tool life of milling Ti6A14V with different edge radius, it can be seen that when the cutting length is the same the tool wear rate is different with the variation of edge radius and the cutting force is different too.
4. The influence of edge preparation tool on the surface quality integrity of milling Ti6A14V was investigated in experiments of milling Ti6A14V with tools of edge preparation and edge unpreparation.
本文以铣削Ti6Al4V刀具切削刃刃口钝化结构为研究对象,通过有限元仿真方法,以最低切削温度为优化指标,对适合铣削Ti6Al4V刀具的刃口钝化结构进行了优化；并通过铣削Ti6Al4V过程中切削力、切削温度、切屑形貌、刀具寿命、表面质量完整性分析,研究了不同刃口钝化结构对铣削Ti6Al4V加工过程的影响。
1.基于Power-Law模型建立Ti6Al4V的本构关系模型,并对三维铣削过程进行了二维简化,建立了能够反映刃口特点的刀片模型,并通过仿真切削力与实验结果的对比,验证了有限元模型的正确性。
2.通过切削力、切削温度的对比,研究了不同刃口钝圆半径及不同刃口复合结构对铣削Ti6Al4V的影响规律,并以最低切削温度为优化指标,对适合铣削Ti6Al4V的刃口钝圆半径及刃口复合结构进行了优化。
3.通过不同刃口钝圆半径的刀具铣削Ti6Al4V的刀具寿命试验研究,发现在相同切削条件下,当切削路程相同时,不同钝圆半径的刀具磨损速度是不同的,切削力的大小也是不同的。
4.通过刃口钝化型式为钝圆刃的刀具与刃口未钝化刀具铣削Ti6Al4V试验,揭示刃口钝化刀具对于铣削Ti6Al4V表面质量完整性的影响规律及作用机理。
Ti6A14V are extensively used in aerospace industry because of their excellent properties of high specific strength (strength-to-weight ratio), fracture resistant characteristics, and their exceptional resistance to corrosion. However, Ti6A14V are considered as typical difficult-to-cut materials due to their high temperature strength, high chemical reactivity and its low modulus of elasticity. During milling Ti6A14V, as a result of low conductivity and short contact length between chip and rake face, the cutting heat can not diffuse easily and only concentrate around the deformation area and the cutting edge. Thus, the temperature of the cutting edge should be very high. What's more, the load on the cutting edge is discontinuous as milling Ti6A14V, so the cutting edge could be easily worn. Cutting tool's structure, especially its tool edge preparation, becomes one of the key factors that influence the tool life and improve machining efficiency. In this paper, some researches were carried out on the tool edge preparation by FEM analysis and the edge preparation size for milling Ti6A14V was optimized aimed at the lowest cutting temperature. The influence of different edge preparation on milling Ti6A14V was investigated by analysis the cutting force, cutting temperature, chip geometries, tool life and surface quality integrity.
1. The constitutive material model of Ti6A14V was built based on Power-Law.3D milling process was simplified into 2D and the model of insert was also built to reflect the characteristics of the cutting edge. At last, the FEM model was verified to be accurate due to FEM cutting forces and experiment forces.
2. By comparison of cutting force and cutting temperature, the influences of different edge radius and edge composite structures on milling Ti6A14V were investigated. Aimed at the lowest cutting temperature, edge radius and edge composite structure were optimized for milling Ti6A14V.
3. In the experiment about tool life of milling Ti6A14V with different edge radius, it can be seen that when the cutting length is the same the tool wear rate is different with the variation of edge radius and the cutting force is different too.
4. The influence of edge preparation tool on the surface quality integrity of milling Ti6A14V was investigated in experiments of milling Ti6A14V with tools of edge preparation and edge unpreparation.
引文
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[14]Vigneau, J., Derrien, S., High speed milling of difficult to machine alloys [C]. First French and German Conference on High Speed Machining.1997.
[15]刘春生,刘雨辰.从航空工业需求看未来刀具的发展[J],航空制造技术.2009(9)：62-66
[16]刘战强.先进刀具设计技术：刀具结构、刀具材料与涂层技术[J].航空制造技术.2006(7)：38-42.
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[18]Tarng Y S, Young H T, Lee B Y. Analytical model of chatter vibration in metal cutting [J]. Int.J Mach.Tools Manuf.1994,34(2):183-197
[19]桂育鹏.刀具刃口钝化技术的探讨[J].数控机床市场.2005.12
[20]J.D.安格纽.金属切削刀具的刃区参数选择[J].Toolong&Froduction.1973.2
[21]J. Rech, Y. C. Yen, M.J.Schaff, et al. Influence of cutting edge radius on the wear resistance of PM-HSS milling inserts [J]. Wear,2005 (259):1168-1176
[22]Yung-Chang Yen, Anurag Jain, Taylan Altan. A finite element analysis of orthogonal machining using different tool edge geometries [J]. Journal of Materials Processing Technology,2004(146): 72-81
[23]K. Shintani, M. Ueki, Y. Fujimura. Optimum tool geometry of CBN tool for continuous turning of carburized steel [J]. International Journal of Machine Tools and Manufacture,1989,29(3): 403-413
[24]Jeffrey D, Thiele, Shreyes N. Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel [J]. Journal of Materials Process Technology,1999(94):216-226
[25]Jiang Hua, Rajiv Shivpuri, Xiaomin Cheng, et al. Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer+hone cutting edge geometry [J]. Materials Science and Engineering A,2005,394(1): 238-248
[26]N. Fang, Q. Wu. The effects of chamfered and honed tool edge geometry in machining of three aluminum alloys [J]. International Journal of Machine Tools & Manufacture,2005 (45): 1178-1187
[27]M. R. Movahhedy, Y Altintas, M. S. Gadala. Numerical analysis of metal cutting with chamfered and blunt tools [J]. ASME,2002 (124):178-188
[28]K.-D.Bouzakis, N. ichailidis, G. Skordaris, et al. Optimisation of the cutting edge roundness and its manufacturing procedures of cemented carbide inserts, to improve their milling performance after a PVD coating deposition [J]. Surface and Coatings Technology,2003(163-164):625-630
[29]E.勒兹D.莫斯可威兹,J.E.小麦叶尔,D.J.斯道菲.金属切削刀具的刃区参数与耐用度的关系[J].American Society of Mechanical Engineers
[30]M.E.Mechant. Basic Mechanics of the Metal Cutting Process [J]. J. Appl. Mech,1944 (11): A168-A175.
[31]M.E.Mechant. Mechanics of Metal Cutting Process [J]. J.Appl. Phys,1951 (16):5-6
[32]V.Piispanen. Theory of Formation of Metal Cutting Process [J]. J.Appl.Phys,1945 (16): 267-318.
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