模具钢硬态切削过程刀具磨损及表面淬火效应研究
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摘要
硬态切削工艺由于具有良好的加工环保性和加工柔性，该工艺已逐步取代磨削工艺成为模具钢的精加工工艺，它是具有广泛应用前景的先进加工技术。但硬态切削加工工艺中诸如刀具磨损、切削过程热流特性和已加工表面完整性等方面的理论与技术还存在诸多没有彻底揭示之处。所以应该在上述方面展开深入研究，以便促进此新兴工艺在实际加工中的应用。
为了建立切削过程的精确仿真模型，本研究系统阐述了切削仿真技术的关键技术，并采用仿真手段利用Abaqus软件研究了工件材料本构关系，针对典型高强度钢Cr12MoV的霍普金森实验得到了工件材料Joshon-Cook模型参数的敏感性关系；联合综合优化软件Isight，通过Abaqus仿真软件的二次开发实现了切削力的仿真控制，为选择合适的切削条件提供理论工具。
为实现模具钢硬态切削过程中刀具磨损的机理研究，本文揭示了PCBN刀具切削模具钢Cr12MoV过程的刀具磨损规律，研究了刀具磨损量对切屑生成机制、切削力、切削应力和切削温度的变化规律；采用功率谱均方根的方法研究了不同切削条件下系统稳定性判据的变化规律，并通过数值建模的方法得到了刀具磨损对切削系统稳定阈极限的影响，结果显示在选定切削条件下刀具磨损加剧会导致切削稳定阈极限变宽。
为揭示硬态切削过程已加工表面淬火效应，本文研究了不同升温速率下工件材料相变点在切削状态下相变图谱位移情况；结合数值方法得到了不同刀具磨损情况下工件温度场分布情况，对已加工表面的变质层厚度进行了预测，并利用实验手段得到了已加工表面变质层受刀具磨损和切削速度的影响规律，同时也分析了淬火效应对已加工表面硬度的影响。
为揭示条件对已加工表面完整性的影响机制，本文研究了硬态切削工艺切削条件对表面粗糙度的影响，建立了考虑最小切削厚度表面粗糙度仿真模型，并采用实验手段验证了模型精度；分析了刀具磨损对加工表面形貌的影响；研究了切削条件、刀具圆弧半径和刀具磨损对残余应力分布的影响机制。
本文以PCBN刀具硬态切削模具钢Cr12MoV工艺为研究对象，通过理论分析、数值模拟和切削试验相结合的方法，在刀具磨损、已加工表面淬火效应和表面完整性等方面研究了硬态切削机理，研究结果可为模具钢硬态切削加工技术推广提供理论依据和技术支撑。
Hard cutting processing technology has gradually become a high strength steelfinishing process and has replaced the grinding process in certain occasions aswell, for its good processing environmental protection, flexible and precision.Thus, this technology is an advanced processing technology with wideapplication prospects. But many special cutting law of the hard cuttingprocessing technology still need to explore, especially cutting tool wear incutting, surface quenching effect, processing surface integrity and other aspectsof the theory and technology need a systemic research, which could furtherpromote the advanced technology.
In order to establish the precise cutting process simulation model, this studyintroduced the key technology of the cutting simulation technology andresearched the workpiece material constitutive relation using Abaqus softwarewith the simulation method, in view of the typical high strength steel Cr12MoVof the Hopkinson experiment get the parameter sensitivity relationship ofmaterial Joshon-Cook model. Through the secondary development of Abaqussimulation software and combining multidisciplinary system optimization Isightsoftware to realize the control of cutting force, which provide theoretical toolsthe choice of appropriate cutting conditions.
The system studied the tool wear mechanism of the process that PCBN toolscut die steel Cr12MoV, and analyzed the change rules of the tool wear amount tochip generation, cutting force, cutting stress and cutting temperature; The systemused the way of root mean square to study the change rules of the system stabilityin different cutting rate and tool wear quantity, and through the numericalmodeling ways to get the influence of the tool wear to cutting system stability,and realized the prediction of the stability domain limit with the simulationmethod.
In order to reveal the die steel Cr12MoV already processing surface quenchingeffect mechanism, this paper studied the workpiece material phase transition point in different heating rate and the phase diagram of displacement in differentcutting state; Combining with numerical method to get the workpiecetemperature field distribution in the different tool wear condition, and predictingthe thickness of already processing surface metamorphic layer, beside, by usingexperimental method to get the influence mechanism of the tool wear and cuttingspeed to finished surface metamorphic layer. At the same time, the paper alsoevaluated how quenching effect influence the processing surface hardness.
This paper has studied the effect of cutting conditions on surface roughness inthe hard cutting processing, and established the minimum cutting thicknesssurface roughness simulation model, and verified the accuracy of model meanscombining with the experiment; it also has analyzed the effect of tool wear onmachining surface morphology and the side flow generation mechanism underdifferent cutting conditions, done a systematic research on influence of cuttingcondition, tool nose radius and tool wear on residual stress distribution.
In this study PCBN tool hard cutting die steel Cr12MoV process as theresearch object, through the combination of theoretical analysis, numericalsimulation and cutting test, study hard state cutting mechanism in the tool wear，processed surface quenching effect surface integrity and other aspects, the resultscould provide the theory basis and the technical support for application of hardcutting processing technology.
为了建立切削过程的精确仿真模型，本研究系统阐述了切削仿真技术的关键技术，并采用仿真手段利用Abaqus软件研究了工件材料本构关系，针对典型高强度钢Cr12MoV的霍普金森实验得到了工件材料Joshon-Cook模型参数的敏感性关系；联合综合优化软件Isight，通过Abaqus仿真软件的二次开发实现了切削力的仿真控制，为选择合适的切削条件提供理论工具。
为实现模具钢硬态切削过程中刀具磨损的机理研究，本文揭示了PCBN刀具切削模具钢Cr12MoV过程的刀具磨损规律，研究了刀具磨损量对切屑生成机制、切削力、切削应力和切削温度的变化规律；采用功率谱均方根的方法研究了不同切削条件下系统稳定性判据的变化规律，并通过数值建模的方法得到了刀具磨损对切削系统稳定阈极限的影响，结果显示在选定切削条件下刀具磨损加剧会导致切削稳定阈极限变宽。
为揭示硬态切削过程已加工表面淬火效应，本文研究了不同升温速率下工件材料相变点在切削状态下相变图谱位移情况；结合数值方法得到了不同刀具磨损情况下工件温度场分布情况，对已加工表面的变质层厚度进行了预测，并利用实验手段得到了已加工表面变质层受刀具磨损和切削速度的影响规律，同时也分析了淬火效应对已加工表面硬度的影响。
为揭示条件对已加工表面完整性的影响机制，本文研究了硬态切削工艺切削条件对表面粗糙度的影响，建立了考虑最小切削厚度表面粗糙度仿真模型，并采用实验手段验证了模型精度；分析了刀具磨损对加工表面形貌的影响；研究了切削条件、刀具圆弧半径和刀具磨损对残余应力分布的影响机制。
本文以PCBN刀具硬态切削模具钢Cr12MoV工艺为研究对象，通过理论分析、数值模拟和切削试验相结合的方法，在刀具磨损、已加工表面淬火效应和表面完整性等方面研究了硬态切削机理，研究结果可为模具钢硬态切削加工技术推广提供理论依据和技术支撑。
Hard cutting processing technology has gradually become a high strength steelfinishing process and has replaced the grinding process in certain occasions aswell, for its good processing environmental protection, flexible and precision.Thus, this technology is an advanced processing technology with wideapplication prospects. But many special cutting law of the hard cuttingprocessing technology still need to explore, especially cutting tool wear incutting, surface quenching effect, processing surface integrity and other aspectsof the theory and technology need a systemic research, which could furtherpromote the advanced technology.
In order to establish the precise cutting process simulation model, this studyintroduced the key technology of the cutting simulation technology andresearched the workpiece material constitutive relation using Abaqus softwarewith the simulation method, in view of the typical high strength steel Cr12MoVof the Hopkinson experiment get the parameter sensitivity relationship ofmaterial Joshon-Cook model. Through the secondary development of Abaqussimulation software and combining multidisciplinary system optimization Isightsoftware to realize the control of cutting force, which provide theoretical toolsthe choice of appropriate cutting conditions.
The system studied the tool wear mechanism of the process that PCBN toolscut die steel Cr12MoV, and analyzed the change rules of the tool wear amount tochip generation, cutting force, cutting stress and cutting temperature; The systemused the way of root mean square to study the change rules of the system stabilityin different cutting rate and tool wear quantity, and through the numericalmodeling ways to get the influence of the tool wear to cutting system stability,and realized the prediction of the stability domain limit with the simulationmethod.
In order to reveal the die steel Cr12MoV already processing surface quenchingeffect mechanism, this paper studied the workpiece material phase transition point in different heating rate and the phase diagram of displacement in differentcutting state; Combining with numerical method to get the workpiecetemperature field distribution in the different tool wear condition, and predictingthe thickness of already processing surface metamorphic layer, beside, by usingexperimental method to get the influence mechanism of the tool wear and cuttingspeed to finished surface metamorphic layer. At the same time, the paper alsoevaluated how quenching effect influence the processing surface hardness.
This paper has studied the effect of cutting conditions on surface roughness inthe hard cutting processing, and established the minimum cutting thicknesssurface roughness simulation model, and verified the accuracy of model meanscombining with the experiment; it also has analyzed the effect of tool wear onmachining surface morphology and the side flow generation mechanism underdifferent cutting conditions, done a systematic research on influence of cuttingcondition, tool nose radius and tool wear on residual stress distribution.
In this study PCBN tool hard cutting die steel Cr12MoV process as theresearch object, through the combination of theoretical analysis, numericalsimulation and cutting test, study hard state cutting mechanism in the tool wear，processed surface quenching effect surface integrity and other aspects, the resultscould provide the theory basis and the technical support for application of hardcutting processing technology.
引文
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