用于不锈钢半精加工、精加工的正型刀片槽型的研究
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摘要
不锈钢材料具有良好的综合性能,因此越来越多地应用于各行业当中。不锈钢属于韧性材料,加工时不容易断屑。目前国内刀具厂家生产用于加工不锈钢的正型刀片断屑效果、使用寿命都不太理想,其市场基本上被国外刀具厂所占领。因此,开展加工不锈钢正型刀片断屑槽的断屑研究,探讨断屑槽的断屑机理,加快适合不锈钢等难加工材料的槽型刀片的开发,提高我国用于不锈钢加工的槽型刀片的自主开发能力具有重大的现实意义。
本文较为系统、深入和全面地综述了国内外槽型刀片切屑控制和断屑槽的研究概况以及所取得的成果；从分析国外最先进的2种加工不锈钢断屑槽刀片入手,对这些刀片进行测绘、切削对比试验,对槽型结构进行了系统分析,对这些典型槽型刀片的断屑性能和耐磨性进行了比较分析。根据试验结果分析研究得出：刃宽、前角、刃倾角是正型刀片进行切削不锈钢产品时起关键作用的槽型参数。
在上述理论研究和切削试验的基础上,提出了加工不锈钢正型刀片断屑槽的设计方案,设计开发了用于半精加工、精加工的5个(C型、D型、S型、T型、V型)正型刀片品种,其中包含了50多个规格的槽型刀片。将研制的不锈钢加工正型刀片与国外同类刀片进行对比切削试验,试验结果表明：所研制的正型刀片在切削过程中平稳轻快、排屑流畅,其断屑范围、耐磨性、表面粗糙达到了国外先进刀具生产厂家同类产品水平。这些开发的产品现已打进国内外市场,取得了较好的技术和经济效益。
Stainless steel material is widely used in various industrial fields for its excellent synthetic property. Stainless Steel is a ductile material, and it is not to broken chip in machining. The domestic manufacturers to produce tools for the processing of stainless steel cutting blade is not effective in chip breaking, its life is short. Its market is largely occupied by foreign tools. Therefore, it is significant to research the positive inserts'grooves for stainless steel machining and so we can know about the broken mechanism of broken grooves, quicken the process of developing broken grooves for hard machining material, improve our self-independent developing ability.
The paper systematically summarizes the background and tendency of the development of chip control and the design of Cemented Carbide Indexable Inserts chip-breaking groove that developed in homeland and foreign countries; through the analysis of the two kinds of advanced foreign chip-breaking grooves and abundant experiments, and compared these typical chip breaking groove of the properties and wear resistance. According to the results, We can conclude:blade width, rake angle, edge angle play a key role in the groove parameters.
Based on the mentioned theory and experiment, the chip-breaking groove design is proposed, two sorts of grooves cutting tools contained more than fifty standards in the M series are developed, and these tools are applied in Stainless steel machining. The development of stainless steel positive inserts is compared with similar foreign inserts cutting test. The results showed that:The cutting process is more stable and faster, and the chips could be removal out fluently. In general, its cutting performance has achieved the same level as the foreign advanced cutting tool. Those designs have been transmuted into finished products that have been sold to domestic and foreign markets, and achieved perfect technologic and economic benefits.
本文较为系统、深入和全面地综述了国内外槽型刀片切屑控制和断屑槽的研究概况以及所取得的成果；从分析国外最先进的2种加工不锈钢断屑槽刀片入手,对这些刀片进行测绘、切削对比试验,对槽型结构进行了系统分析,对这些典型槽型刀片的断屑性能和耐磨性进行了比较分析。根据试验结果分析研究得出：刃宽、前角、刃倾角是正型刀片进行切削不锈钢产品时起关键作用的槽型参数。
在上述理论研究和切削试验的基础上,提出了加工不锈钢正型刀片断屑槽的设计方案,设计开发了用于半精加工、精加工的5个(C型、D型、S型、T型、V型)正型刀片品种,其中包含了50多个规格的槽型刀片。将研制的不锈钢加工正型刀片与国外同类刀片进行对比切削试验,试验结果表明：所研制的正型刀片在切削过程中平稳轻快、排屑流畅,其断屑范围、耐磨性、表面粗糙达到了国外先进刀具生产厂家同类产品水平。这些开发的产品现已打进国内外市场,取得了较好的技术和经济效益。
Stainless steel material is widely used in various industrial fields for its excellent synthetic property. Stainless Steel is a ductile material, and it is not to broken chip in machining. The domestic manufacturers to produce tools for the processing of stainless steel cutting blade is not effective in chip breaking, its life is short. Its market is largely occupied by foreign tools. Therefore, it is significant to research the positive inserts'grooves for stainless steel machining and so we can know about the broken mechanism of broken grooves, quicken the process of developing broken grooves for hard machining material, improve our self-independent developing ability.
The paper systematically summarizes the background and tendency of the development of chip control and the design of Cemented Carbide Indexable Inserts chip-breaking groove that developed in homeland and foreign countries; through the analysis of the two kinds of advanced foreign chip-breaking grooves and abundant experiments, and compared these typical chip breaking groove of the properties and wear resistance. According to the results, We can conclude:blade width, rake angle, edge angle play a key role in the groove parameters.
Based on the mentioned theory and experiment, the chip-breaking groove design is proposed, two sorts of grooves cutting tools contained more than fifty standards in the M series are developed, and these tools are applied in Stainless steel machining. The development of stainless steel positive inserts is compared with similar foreign inserts cutting test. The results showed that:The cutting process is more stable and faster, and the chips could be removal out fluently. In general, its cutting performance has achieved the same level as the foreign advanced cutting tool. Those designs have been transmuted into finished products that have been sold to domestic and foreign markets, and achieved perfect technologic and economic benefits.
引文
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[44]P. L. B. Oxley. An analysis for orthogonal cutting with restricted tool-chip contact[J]. Int. J. Mech. Sci.1962(4):129～135
[45]张幼桢.金属切削理论[M].航空工业出版社,1998
[46]李振加.切屑折断机理及其应用[M].大连理工大学出版社,1990：99～115
[47]吴克忠,陈永洁.减摩槽在三维槽型刀片中的应用[J].工具技术,2005,39(5)：53～55
[48]傅华,陈永洁.带减摩槽刀片切削机理的研究[J].工具技术,1998,32(2)：7～10
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[2]胡名洋.国内外特殊钢市场与竞争力分析.中国特钢企业协会2003年特殊钢论坛
[3]王适,李振加等.确定切屑折断最小极限切削深度的理论探讨[J].哈尔滨理工大学学报,1999,4(4)：54～57
[4]www.kscjmy.com/Technique/qxjs/200905/1322.html
[5]张远志.我国金属切削刀具技术发展对策研究[J].科技进步与对策,2002,2(4)：61～67
[6]方宁.硬质合金刀片新型断屑槽形及其CAD技术的研究[D].华中科技大学,1994
[7]陈海雷,蒋先刚,涂晓斌.切屑生成、卷曲和折断的理论研究[J].华东交通大学学报,2002,19(2)：45～47
[8]Jawabiris,Lutterveltca. Recent developments in chip control research and applications [J]. Annals of the CIRP,1993,42 (2):659～693
[9]G.V.Stabler. The fundmantal geometry of cutting tool[J]. Proc.Inst.Mach.Eng. 1971,16(5):14～26
[10]L.V.Colwell. Predicting the angle of Chip Flow for single point cutting tools [J]. Trans of the ASME,1954,76(2):199～204
[11]师汉民.切屑的流出、卷曲与折断[J].华中工学院学报,1965,5(7)：66～106
[12]J.K.Russell, R.H.Brown. The measurement of chip flow direction[J]. Int.J.Mach.Tool Des.Tes.,1966,6 (2):129～138
[13]胡荣生,王频.流屑角预报理论[R].中国高校金属切削研究会第四界学术年会科研论文集,北京：机械工业出版社,1991：55～60
[14]张维纪,李加种.斜角切削流屑角的研究[J].浙江大学学报,1987,21(2)：59～63
[15]徐亦红,李振加.流屑角变化规律的研究[J].哈尔滨科技大学学报,1996,20(1)：33～38
[16]师汉民.关于非自由切削的一个数学模型[R].中国高校金属切削研究会中南分会学术年会论文集,武汉,1993：34～41
[17]R.S.Hu. Predicting the angle of chip flow[J]. The 2nd Int.Conf.of Metal Cutting.Wuhan China,1985:23～29
[18]K.Nakayama, M.Ogawa. Basic rules on the form of chip in metal cutting[J]. Annals of CIRP.1978,27(1):17～20
[19]C. Spaans. A systematic approach of three-dimensional chip curl[J]. chip breaking and control,SME Paper,MR70-24,1970
[20]C. Y.Jiang, Y.Z.Zhang, Z.J.Chi, Experimental research of the chip flow direction and its application to the chip control[J]. Annals of the CIRP,1984,33(1):81～84
[21]K.nakayama,M.Arai. Comprehensive chip form classication based on the cut mechanism[J]. Annals of the CIRP,1992,41(1):71～74
[22]K.Nakayama,M.Ogawa. Basic rules on the form of chip in metal cutting[J]. Annals of CIRP,1978,27(1):17～20
[23]陈永洁,黄威武.切屑三维卷曲的运动学分析[J].中国机械工程,2000,11(5)：513～515
[24]王频.数控机床可转位刀片断屑槽断屑机理的研究及其应用[D].大连：大连理工大学,1994：131～137
[25]中山一雄,李云芳译.金属切削加工理论[M].机械工业出版社,1988
[26]张幼桢.金属切削理论[M].航空工业出版社,1988：50～6
[27]张成恩.断屑机理与断屑措施[J].湖南机械,1982(2)：48～64
[28]林其广,罗秉宁.断屑原理和断屑方法[J].国外金属加工,1981(3)：10～14
[29]王贵成.切削加工中的切屑控制技术[J].组合机床与自动化加工技术,1989(4)：42～45
[30]戴恩期.不锈钢加工中切削液的选择[J].润滑与密封,2003,(2)：102～103
[31]宠爱芳.数控车床切屑控制的有效方法[J].机械工业自动化,1991(2)：5～9
[32]Fang N, Wu Q. Impulsive chip breaking in metal machining:A proof-of-concept study [J]. Machining Science and Technology,2006,10(2):251～262
[33]陈维福.车刀用上置式断屑器[J].工具技术,1990,24(3)：28～31
[34]宠爱芳.断屑技术[M].国防工业出版社.1991：25～40
[35]C.Spaans, P. F. H. J, Van Geel. Break Mechanisms in Cutting with a chip-breaker [J]. Annals of the CIRP,1970,18(1):87～92
[36]C.Spaans. The fundamentals of three-dimensional chip curl, chip breaking and chip control[J]. Doctor thesis. T. H. Delft.1971:32～55
[37]B. Worthington. The effect of rake face configuration on the curvature of the chip in metal cutting. Int.J.Mach[J].Tool Des.Res.1975,5(4):223～239
[38]B. Worthington. The operation and performance of a groove-type chip Forming device[J]. Int. J.Prod. Res.1976,14(5):529～558
[39]B.Worthington,M.H.Rahman. Predicting breaking with groove type breakers[J]. Int.J.Mach. Tool Des. Res.1979,19(3):121～132
[40]B.Worthingdon. A comprehensive literature survey of chip control in the turning process[J]. The Macmillan Press Ltd.1977:103～116
[41]R. Ghosh. Chip breakability assessment using a chip-groove classification system in finish turning[J]. Trans of the ASME.1995:679～701
[42]P. L. B. Oxley. Mechanics of metal cutting. Proceedings of International Production Engineering Research Conference, Pittsburgh,1963:49～50
[43]I. S. Jawahir and P.L.B. Oxley. Efficient chip control at reduced power consumption: An Experimental Analysis [C]. Proceedings of the 4th International Conference on Manufacturing Engineering,Brisbane, Australia,1988:311～316
[44]P. L. B. Oxley. An analysis for orthogonal cutting with restricted tool-chip contact[J]. Int. J. Mech. Sci.1962(4):129～135
[45]张幼桢.金属切削理论[M].航空工业出版社,1998
[46]李振加.切屑折断机理及其应用[M].大连理工大学出版社,1990：99～115
[47]吴克忠,陈永洁.减摩槽在三维槽型刀片中的应用[J].工具技术,2005,39(5)：53～55
[48]傅华,陈永洁.带减摩槽刀片切削机理的研究[J].工具技术,1998,32(2)：7～10
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