高速断续切削淬硬钢刀具失效机理研究
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摘要
为获取好的加工质量以及高的加工效率,制造业中已广泛应用高速切削加工技术。本文针对高速断续切削淬硬钢条件下的刀具失效机理,进行了一系列理论及实验研究。基于损伤力学理论,建立了高速断续车削淬硬条件下的刀具损伤模型以及刀具寿命预测模型,结合实验分析了刀具损伤失效机理并对刀具寿命以及刀具失效演变进行了预测。基于传热学理论,建立了高速平面铣削淬硬钢条件下的刀具瞬时平均温度模型,以刀具温度理论研究结果为切入点,针对等金属去除率条件下的刀具失效机理进行了实验研究。通过高速平面铣削淬硬钢实验,确定了关于切削力、加工表面粗糙度以及刀具寿命的临界切削速度,分析、对比并揭示了不同切削速度区间内的刀具失效机理,并明确了临界切削速度两侧速度范围内各切削参数对切削力、加工表面粗糙度以及刀具寿命的影响。
基于连续介质损伤力学,建立了高速断续车削淬硬钢陶瓷刀具损伤模型,对刀具损伤演变进行了理论研究。刀具材料的损伤累积是由晶间微裂纹的扩展所导致的,提出了确定刀具材料初始以及临界损伤值的数学方法。采用损伤当量应力最大值(MDES)对刀具损伤进行了分析,结果表明：发生在刀具前刀面的断裂要比后刀面处更为严重；较小的切出角有利于降低刀具材料断裂的可能性；较小的刀具前角,增大了刀具前刀面在切入工件阶段发生断裂的可能性,而降低了刀具后刀面在整个切削阶段发生断裂的可能性；刀具后角增大时,刀具后刀面更易发生大面积断裂。
通过高速断续车削淬硬钢实验,结合刀具材料损伤模型的理论研究结果,对两种A12O3/(W, Ti)C陶瓷刀具的失效机理进行了实验研究。结果表明,各切削参数对刀具寿命的影响大小顺序为：切削速度、背吃刀量、进给量。机械载荷对刀具失效的影响由磨损初期的相对较强转变为后期的相对较弱,而热载荷影响的变化过程则与之相反。较低切削速度下,机械载荷导致刀具材料微细观损伤破坏,并最终导致刀具材料宏观疲劳裂纹扩展。较高切削速度下,高的刀具温度导致刀具材料力学性能下降,使得刀具材料产生热损伤,在机械、热载荷的复合作用下,刀具材料最终发生局部断裂。结合损伤模型建立的刀具寿命预测模型能够较好得预测刀具失效演变以及刀具寿命。
建立了高速平面铣削淬硬钢刀具瞬时平均温度模型。此模型可用于计算刀具任意深度处的瞬时平均温度。针对等金属去除率条件下的9种切削方式的刀具温度进行了理论计算以及对比分析,发现了切削周期内刀具温度峰值的差异性。本刀具温度模型为优化切削条件、刀具几何参数等提供了理论依据,深化了对刀具温度的认识。
基于刀具温度理论研究结果,设计并进行了等金属去除率条件下的高速平面铣削淬硬钢实验,对CBN刀具失效机理进行了实验研究。当切削速度升高时,正常磨损阶段缩短且刀具磨损速率升高。较低切削速度下,刀具前、后刀面的失效机理为磨粒磨损与粘结磨损。在较高切削速度下,由于更加强烈的热、机械冲击,刀具前刀面更易发生剥落,并且较高的切削温度削弱了刀具材料的机械性能,当受到较大机械载荷时,刀具后刀面更易发生断裂。较低切削速度下,刀具材料应具备足够抵抗粘结磨损的能力。在较高切削速度下,刀具材料的高温力学性能以及抵抗机械冲击的能力尤为重要。
通过硬质合金涂层刀具高速平面铣削淬硬钢实验,对临界切削速度进行了实验研究。当采用临界切削速度1400m/min时,可同时获取较低的切削力、较低的加工表面粗糙度、较高的刀具寿命。当切削速度超过1400m/min后,切削速度以及每齿进给量对切削力以及加工表面粗糙度的影响程度增大；切削速度对刀具寿命的影响程度增大。在速度区间200m/min～1000m/min内,刀具失效机理为发生在刀具后刀面上的磨粒磨损、粘结磨损和氧化磨损。在速度区间1000m/min～1400m/min内,受较高强度机械冲击以及热冲击的影响,前刀面和切削刃处分别出现涂层剥落和微崩刃。在速度区间1400m/min～2400m/min内,更高的刀具温度以及更高强度的机械、热冲击导致刀具前刀面出现大面积剥落。
In order to acquire good surface finish and high machining efficiency, high-speed machining (HSM) technology has been widely applied in manufacturing process. In the present study, the tool wear mechanisms in high-speed intermittent cutting of hardened steel were investigated theoretically and experimentally. Tool damage model and tool life prediction model were proposed in order to identify the tool wear mechanisms and predict the tool life and the tool wear evolution in high-speed intermittent turning of hardened steel. An analytical model was built to calculate and analyze the transient average tool temperatures in high-speed face milling of hardened steel. High-speed face milling experiments were designed and conducted with the calculated results of tool temperature considered. The wear mechanisms of tools tested with fixed metal removal rate and different cutting speeds were investigated. High-speed face milling of hardened steel was performed in order to explore the critical cutting speeds for cutting force, surface roughness and tool life. The tool wear mechanisms obtained in different cutting speed ranges were distinguished. The effects of cutting parameters on cutting force, surface roughness and tool life were investigated in different cutting speed regions divided by the critical cutting speed.
Ceramic tool damage model was constructed based on continuum damage mechanics for high-speed intermittent turning of hardened steel. Theoretical analysis of tool damage mechanisms were conducted based on the established model. The tool damage accumulation can be attributed to the growth of the microcrack at the grain boundary. A mathematical method was applied to calculate the initial and critical damage value of the tool material. The concept of maximum damage equivalent stress (MDES) was proposed to analyze the tool damage mechanisms. The analysis results showed that fracture happened on the tool rake face was more serious than that happened on flank face. Lower exit angle was beneficial for reducing the degree of tool fracture. Smaller rake angle enhanced the possibility of fracture happened on the rake face at the initial cutting stage and reduced that of fracture happened on the flank face in the whole cutting process. When the clearance angle increased, larger fractured area was more likely to arise on the flank face.
Taking the theoretical analysis results of tool damage mechanisms into consideration, high-speed intermittent turning of hardened steel was conducted in order to investigate the ceramic tool wear mechanisms. The contribution orders of cutting parameters for tool life was cutting speed, depth of cut and feed rate. The mechanical load influenced more on tool wear at the early stage of tool wear evolution process than it did in the whole tool life, while the thermal load influenced in the opposite way. At relatively low cutting speed, the mechanical load caused microscale damage of the tool material, leading to the fatigue crack growth. When the cutting speed was relatively high, the mechanical properties of the tool material were weakened due to the thermal damage caused by high tool temperature. Regional fracture happened on the tool because of the combined effects of mechanical and thermal loads. The established tool life prediction model can be used to predict tool life and tool wear evolution with acceptable level of accuracy.
A transient average tool temperature model was established for high-speed face milling of hardened steel. This model can be applied to evaluate the transient average tool temperatures at any depth of the cutting tool. Based on the established model, the transient average tool temperatures for nine different cutting conditions with fixed cutting speed and metal removal rate were calculated and analyzed in order to identify the differences of the maximum tool temperatures. The proposed theoretical method increased the understanding of tool temperatures in face milling process without costly experimental time. Furthermore, it provided theoretical basis for the design of cutting tool.
Based on the theoretical analysis of tool temperature, high-speed face milling of hardened steel was designed and conducted to investigate the CBN tool wear mechanisms experimentally. When the cutting speed increased, the normal wear stage became shorter and the tool wear rate growed larger. At relatively low cutting speed, the wear mechanisms of tool rake and flank faces were abrasive wear and adhesive wear. Due to the severer mechanical and thermal impact, flaking was likely to happen when the cutting speed was relatively high. Since the mechanical properties were weakened by the high cutting temperature, fracture was more inclined to arise on the tool flank face when relatively higher mechanical load is applied. For the purpose of acquiring high tool life of the CBN tool, the tool material should have sufficient capability of resisting adhesion when tested at relatively low cutting speed. At relatively high cutting speed, retention of mechanical properties to high cutting temperature and resistance to mechanical impact were crucial for enhancing the tool life.
High-speed face milling of hardened steel with coated cemented carbide tool used was performed in order to investigate the critical cutting speed. At the critical cutting speed of1400m/min, relatively low cutting force, relatively low surface roughness Ra and relatively long tool life can be obtained at the same time. When the cutting speed surpassed1400m/min, cutting speed and feed per tooth became much more influential to cutting force and surface roughness Ra. As for tool life, the effect of cutting speed increased. When the tools were tested within cutting speed range200m/min～1000m/min, the main tool wear mechanisms were abrasive wear, adhesive wear and oxidation wear which mostly influenced the tool flank face. When the cutting speed was between1000m/min and1400m/min, owing to the severer mechanical and thermal impact resulting from the higher cutting speed, coating delamination and microchipping happened on the tool rake face and cutting edge, respectively. As the cutting speed increased from1400m/min to2400m/min, abrupt flaking occurred on the tool rake face due to the increase of tool temperature, mechanical impact and thermal impact.
基于连续介质损伤力学,建立了高速断续车削淬硬钢陶瓷刀具损伤模型,对刀具损伤演变进行了理论研究。刀具材料的损伤累积是由晶间微裂纹的扩展所导致的,提出了确定刀具材料初始以及临界损伤值的数学方法。采用损伤当量应力最大值(MDES)对刀具损伤进行了分析,结果表明：发生在刀具前刀面的断裂要比后刀面处更为严重；较小的切出角有利于降低刀具材料断裂的可能性；较小的刀具前角,增大了刀具前刀面在切入工件阶段发生断裂的可能性,而降低了刀具后刀面在整个切削阶段发生断裂的可能性；刀具后角增大时,刀具后刀面更易发生大面积断裂。
通过高速断续车削淬硬钢实验,结合刀具材料损伤模型的理论研究结果,对两种A12O3/(W, Ti)C陶瓷刀具的失效机理进行了实验研究。结果表明,各切削参数对刀具寿命的影响大小顺序为：切削速度、背吃刀量、进给量。机械载荷对刀具失效的影响由磨损初期的相对较强转变为后期的相对较弱,而热载荷影响的变化过程则与之相反。较低切削速度下,机械载荷导致刀具材料微细观损伤破坏,并最终导致刀具材料宏观疲劳裂纹扩展。较高切削速度下,高的刀具温度导致刀具材料力学性能下降,使得刀具材料产生热损伤,在机械、热载荷的复合作用下,刀具材料最终发生局部断裂。结合损伤模型建立的刀具寿命预测模型能够较好得预测刀具失效演变以及刀具寿命。
建立了高速平面铣削淬硬钢刀具瞬时平均温度模型。此模型可用于计算刀具任意深度处的瞬时平均温度。针对等金属去除率条件下的9种切削方式的刀具温度进行了理论计算以及对比分析,发现了切削周期内刀具温度峰值的差异性。本刀具温度模型为优化切削条件、刀具几何参数等提供了理论依据,深化了对刀具温度的认识。
基于刀具温度理论研究结果,设计并进行了等金属去除率条件下的高速平面铣削淬硬钢实验,对CBN刀具失效机理进行了实验研究。当切削速度升高时,正常磨损阶段缩短且刀具磨损速率升高。较低切削速度下,刀具前、后刀面的失效机理为磨粒磨损与粘结磨损。在较高切削速度下,由于更加强烈的热、机械冲击,刀具前刀面更易发生剥落,并且较高的切削温度削弱了刀具材料的机械性能,当受到较大机械载荷时,刀具后刀面更易发生断裂。较低切削速度下,刀具材料应具备足够抵抗粘结磨损的能力。在较高切削速度下,刀具材料的高温力学性能以及抵抗机械冲击的能力尤为重要。
通过硬质合金涂层刀具高速平面铣削淬硬钢实验,对临界切削速度进行了实验研究。当采用临界切削速度1400m/min时,可同时获取较低的切削力、较低的加工表面粗糙度、较高的刀具寿命。当切削速度超过1400m/min后,切削速度以及每齿进给量对切削力以及加工表面粗糙度的影响程度增大；切削速度对刀具寿命的影响程度增大。在速度区间200m/min～1000m/min内,刀具失效机理为发生在刀具后刀面上的磨粒磨损、粘结磨损和氧化磨损。在速度区间1000m/min～1400m/min内,受较高强度机械冲击以及热冲击的影响,前刀面和切削刃处分别出现涂层剥落和微崩刃。在速度区间1400m/min～2400m/min内,更高的刀具温度以及更高强度的机械、热冲击导致刀具前刀面出现大面积剥落。
In order to acquire good surface finish and high machining efficiency, high-speed machining (HSM) technology has been widely applied in manufacturing process. In the present study, the tool wear mechanisms in high-speed intermittent cutting of hardened steel were investigated theoretically and experimentally. Tool damage model and tool life prediction model were proposed in order to identify the tool wear mechanisms and predict the tool life and the tool wear evolution in high-speed intermittent turning of hardened steel. An analytical model was built to calculate and analyze the transient average tool temperatures in high-speed face milling of hardened steel. High-speed face milling experiments were designed and conducted with the calculated results of tool temperature considered. The wear mechanisms of tools tested with fixed metal removal rate and different cutting speeds were investigated. High-speed face milling of hardened steel was performed in order to explore the critical cutting speeds for cutting force, surface roughness and tool life. The tool wear mechanisms obtained in different cutting speed ranges were distinguished. The effects of cutting parameters on cutting force, surface roughness and tool life were investigated in different cutting speed regions divided by the critical cutting speed.
Ceramic tool damage model was constructed based on continuum damage mechanics for high-speed intermittent turning of hardened steel. Theoretical analysis of tool damage mechanisms were conducted based on the established model. The tool damage accumulation can be attributed to the growth of the microcrack at the grain boundary. A mathematical method was applied to calculate the initial and critical damage value of the tool material. The concept of maximum damage equivalent stress (MDES) was proposed to analyze the tool damage mechanisms. The analysis results showed that fracture happened on the tool rake face was more serious than that happened on flank face. Lower exit angle was beneficial for reducing the degree of tool fracture. Smaller rake angle enhanced the possibility of fracture happened on the rake face at the initial cutting stage and reduced that of fracture happened on the flank face in the whole cutting process. When the clearance angle increased, larger fractured area was more likely to arise on the flank face.
Taking the theoretical analysis results of tool damage mechanisms into consideration, high-speed intermittent turning of hardened steel was conducted in order to investigate the ceramic tool wear mechanisms. The contribution orders of cutting parameters for tool life was cutting speed, depth of cut and feed rate. The mechanical load influenced more on tool wear at the early stage of tool wear evolution process than it did in the whole tool life, while the thermal load influenced in the opposite way. At relatively low cutting speed, the mechanical load caused microscale damage of the tool material, leading to the fatigue crack growth. When the cutting speed was relatively high, the mechanical properties of the tool material were weakened due to the thermal damage caused by high tool temperature. Regional fracture happened on the tool because of the combined effects of mechanical and thermal loads. The established tool life prediction model can be used to predict tool life and tool wear evolution with acceptable level of accuracy.
A transient average tool temperature model was established for high-speed face milling of hardened steel. This model can be applied to evaluate the transient average tool temperatures at any depth of the cutting tool. Based on the established model, the transient average tool temperatures for nine different cutting conditions with fixed cutting speed and metal removal rate were calculated and analyzed in order to identify the differences of the maximum tool temperatures. The proposed theoretical method increased the understanding of tool temperatures in face milling process without costly experimental time. Furthermore, it provided theoretical basis for the design of cutting tool.
Based on the theoretical analysis of tool temperature, high-speed face milling of hardened steel was designed and conducted to investigate the CBN tool wear mechanisms experimentally. When the cutting speed increased, the normal wear stage became shorter and the tool wear rate growed larger. At relatively low cutting speed, the wear mechanisms of tool rake and flank faces were abrasive wear and adhesive wear. Due to the severer mechanical and thermal impact, flaking was likely to happen when the cutting speed was relatively high. Since the mechanical properties were weakened by the high cutting temperature, fracture was more inclined to arise on the tool flank face when relatively higher mechanical load is applied. For the purpose of acquiring high tool life of the CBN tool, the tool material should have sufficient capability of resisting adhesion when tested at relatively low cutting speed. At relatively high cutting speed, retention of mechanical properties to high cutting temperature and resistance to mechanical impact were crucial for enhancing the tool life.
High-speed face milling of hardened steel with coated cemented carbide tool used was performed in order to investigate the critical cutting speed. At the critical cutting speed of1400m/min, relatively low cutting force, relatively low surface roughness Ra and relatively long tool life can be obtained at the same time. When the cutting speed surpassed1400m/min, cutting speed and feed per tooth became much more influential to cutting force and surface roughness Ra. As for tool life, the effect of cutting speed increased. When the tools were tested within cutting speed range200m/min～1000m/min, the main tool wear mechanisms were abrasive wear, adhesive wear and oxidation wear which mostly influenced the tool flank face. When the cutting speed was between1000m/min and1400m/min, owing to the severer mechanical and thermal impact resulting from the higher cutting speed, coating delamination and microchipping happened on the tool rake face and cutting edge, respectively. As the cutting speed increased from1400m/min to2400m/min, abrupt flaking occurred on the tool rake face due to the increase of tool temperature, mechanical impact and thermal impact.
引文
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