各向同性热解石墨精密可切削性研究
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摘要
各向同性热解石墨因为其重量轻、高导热率、低摩擦系数、低线膨胀系数、高耐热性、高耐热震性、良好的化学稳定性等优点逐渐被应用于航空发动机涡轮轴密封件当中。但各向同性热解石墨是典型的脆性材料,在加工过程中易出现边缘碎裂、加工表面质量差、成品率低、刀具磨损严重等现象。采用新的加工方法对其进行加工,是提高其生产率和表面质量的关键。
对各向同性热解石墨纳米力学性能的研究,是实现其精密可切削性的基础。本文借助于纳米压痕试验,通过对其载荷—位移曲线的分析,得到其弹性性能(弹性模量E)和塑性性能(纳米硬度H)。同时利用得到的材料力学性能的参数,基于圣维南定理建立了各向同性热解石墨的三维压痕仿真模型;通过有限元软件ABAQUS对其纳米印压过程进行有限元仿真,得到了其塑性性能,以及加载卸载过程中应力的分布的情况。
本文首先通过采用断裂力学和位错力学相结合的方法,利用MATLAB软件模拟石墨晶体在不同载荷条件下的裂纹和位错的作用过程。利用该模拟结果,还研究了刀具前角对各向同性热解石墨晶体脆塑转变的影响,得到了金刚石刀具的最佳前角,并通过试验验证了研究结果。
其次通过精密切削试验,得到了切削速度、进给量和切削深度对表面粗糙度和切削力的影响规律。试验结果表明,进给量对表面粗糙度的影响最大,而且切削力和表面粗糙度都随着进给量的减小而减小。
刀具的磨损直接影响到其表面质量,进而影响其作为密封环的使用性能。本文最后通过单因素试验,对金刚石刀具在不同时刻的磨损情况进行相应的研究,得到了刀具磨损以机械磨损、磨粒磨损、粘结磨损、切削刃的冲蚀为主,可能还存在氧化磨损、粘结磨损。
Isotropic pyrolytic graphite is gradually used in aero-engine turbine shaft seals dues to its light weight, high thermal conductivity, low coefficient of friction, low liner expansible coefficient, high heat resistance, excellent thermal shock resistance and good chemical stability. But the isotropic pyrolytic graphite is a kind of typical brittle material. The fragmentary phenomena of the edge, low machining surface finish, low productivity and cutting tool wears seriously are occurred during the cutting process. It is the key for us to improve the productivity and surface quality to use the new methods for processing it.
The nano-mechanical properties of isotropic pyrolytic graphite is the foundation of precision cutting. The nano-mechanical properties such as Young’s modulus E; the Plastic Property,Hardness H, are obtained by analyzing the load - displacement curve which is obtained through the indentation experiment. The three-dimensional finite element model of indentation process was developed based on the law of Saint-Venant Principle and the material properties which were obtained by the indentation experiments. The process of indentation was simulated by ABAQUS finite element analysis software. The plastic property of this material was obtained. During the loading and unloading processes the stress distributions was also obtained.
Firstly this paper resorts to fracture mechanics and dislocation mechanics, interaction process of cracks and dislocation were simulated through the MATLAB software. The simulation results indicated that there existd optimal loading conditions under which the istropic pyrolytic graphite plastic deformation plastic deformation was involved more easily. Then using the simulation results to research the effect of rake angle on the istropic pyrolytic graphite’s brittle-ductile transition. The optimal rake angle was given. The results were validated through precision cutting experiments.
Then the precision cutting experiments were studied. The laws of surface roughness and cutting force by changing cutting speed, feed rate, cutting depth, and the reasons were analyzed. The feed rate had the biggest effect on surface roughness. The cutting force and the surface roundness reduced with the feed rate decreased off.
Finally tool wear not only affects surface quality but also influences the sealing performance of sealing rings. In order to study the mechanism of the diamond at the differernt period during the cutting process ,the single factor experiment was carried. It showed that the main wear mechanisms were typically mechanical wear, abrasive wear, micro grooves wear, cutting edge erosion wear and possible adhesive wear, oxidation wear.
对各向同性热解石墨纳米力学性能的研究,是实现其精密可切削性的基础。本文借助于纳米压痕试验,通过对其载荷—位移曲线的分析,得到其弹性性能(弹性模量E)和塑性性能(纳米硬度H)。同时利用得到的材料力学性能的参数,基于圣维南定理建立了各向同性热解石墨的三维压痕仿真模型;通过有限元软件ABAQUS对其纳米印压过程进行有限元仿真,得到了其塑性性能,以及加载卸载过程中应力的分布的情况。
本文首先通过采用断裂力学和位错力学相结合的方法,利用MATLAB软件模拟石墨晶体在不同载荷条件下的裂纹和位错的作用过程。利用该模拟结果,还研究了刀具前角对各向同性热解石墨晶体脆塑转变的影响,得到了金刚石刀具的最佳前角,并通过试验验证了研究结果。
其次通过精密切削试验,得到了切削速度、进给量和切削深度对表面粗糙度和切削力的影响规律。试验结果表明,进给量对表面粗糙度的影响最大,而且切削力和表面粗糙度都随着进给量的减小而减小。
刀具的磨损直接影响到其表面质量,进而影响其作为密封环的使用性能。本文最后通过单因素试验,对金刚石刀具在不同时刻的磨损情况进行相应的研究,得到了刀具磨损以机械磨损、磨粒磨损、粘结磨损、切削刃的冲蚀为主,可能还存在氧化磨损、粘结磨损。
Isotropic pyrolytic graphite is gradually used in aero-engine turbine shaft seals dues to its light weight, high thermal conductivity, low coefficient of friction, low liner expansible coefficient, high heat resistance, excellent thermal shock resistance and good chemical stability. But the isotropic pyrolytic graphite is a kind of typical brittle material. The fragmentary phenomena of the edge, low machining surface finish, low productivity and cutting tool wears seriously are occurred during the cutting process. It is the key for us to improve the productivity and surface quality to use the new methods for processing it.
The nano-mechanical properties of isotropic pyrolytic graphite is the foundation of precision cutting. The nano-mechanical properties such as Young’s modulus E; the Plastic Property,Hardness H, are obtained by analyzing the load - displacement curve which is obtained through the indentation experiment. The three-dimensional finite element model of indentation process was developed based on the law of Saint-Venant Principle and the material properties which were obtained by the indentation experiments. The process of indentation was simulated by ABAQUS finite element analysis software. The plastic property of this material was obtained. During the loading and unloading processes the stress distributions was also obtained.
Firstly this paper resorts to fracture mechanics and dislocation mechanics, interaction process of cracks and dislocation were simulated through the MATLAB software. The simulation results indicated that there existd optimal loading conditions under which the istropic pyrolytic graphite plastic deformation plastic deformation was involved more easily. Then using the simulation results to research the effect of rake angle on the istropic pyrolytic graphite’s brittle-ductile transition. The optimal rake angle was given. The results were validated through precision cutting experiments.
Then the precision cutting experiments were studied. The laws of surface roughness and cutting force by changing cutting speed, feed rate, cutting depth, and the reasons were analyzed. The feed rate had the biggest effect on surface roughness. The cutting force and the surface roundness reduced with the feed rate decreased off.
Finally tool wear not only affects surface quality but also influences the sealing performance of sealing rings. In order to study the mechanism of the diamond at the differernt period during the cutting process ,the single factor experiment was carried. It showed that the main wear mechanisms were typically mechanical wear, abrasive wear, micro grooves wear, cutting edge erosion wear and possible adhesive wear, oxidation wear.
引文
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