微织构自润滑与振荡热管自冷却双重效用的干切削刀具的研究
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摘要
本文根据干切削加工的要求,结合表面织构润滑技术与振荡热管冷却技术,提出了自润滑与自冷却双重效用的干切削刀具的概念。研制成功了微织构自润滑与振荡热管自冷却双重效用的干切削刀具,研究了表面织构对硬质合金刀具材料的摩擦磨损特性的影响、振荡热管强化刀具散热的作用效果以及该刀具的切削性能,分析和揭示了该刀具的自润滑与自冷却的作用机理。
在分析刀具切削的摩擦和润滑机理的基础上,提出了微织构自润滑刀具的设计概念,即：在刀具前刀面的刀-屑接触区加工微织构,并在微织构凹槽中填充固体润滑剂,在切削过程中织构凹槽中的固体润滑剂受摩擦挤压作用拖覆在刀-屑接触界面形成润滑膜,实现刀具的自润滑。建立了微织构自润滑刀具的设计模型,结合微织构对刀具应力分布的影响,确定了微织构自润滑刀具的微织构的最佳结构参数：槽型为双椭圆结构,其外椭圆的长径为0.8mm、短径为0.6mm,织构距切削刃距离L为150μm,凹槽中心间距H为150μm,凹槽宽度B为50μm,槽深为100μm。优选了二硫化钼(MoS2)作为微织构自润滑刀具使用的固体润滑剂。采用激光加工技术制备了微织构自润滑刀具。
将振荡热管冷却技术应用到刀具散热上,提出了振荡热管自冷却刀具的设计概念,即：在刀具中嵌入振荡热管,切削过程中,振荡热管因具有优良的导热性能而能够加快切削区温度的导出,从而实现刀具的自冷却。建立了振荡热管自冷却刀具的设计方法,根据刀具切削的温度环境和刀片的结构尺寸,确定振荡热管自冷却刀具的振荡热管使用的工质为水,管壁材料为铜,管的外径和内径分别为2mm和1.2mm,工质充液率为60%。采用电火花加工技术制备了四弯道、六弯道和八弯道三种振荡热管自冷却刀具。
研究了表面织构对硬质合金刀具材料的摩擦磨损特性的影响。将光滑表面试样(SS)、光滑表面抹覆润滑剂的试样(SSL)、表面织构试样(TS)和填充润滑剂的表面织构试样(TSL)与钛合金球对摩进行了对比干摩擦试验,结果表明：与SS试样相比,SSL试样并不能改善硬质合金的摩擦磨损性能,TS试样的摩擦磨损状况更为恶劣,TSL试样能够有效改善硬质合金的摩擦磨损性能；TSL试样相比SS试样降低平均摩擦系数达20-25%,降低摩擦温度达8-15%；硬质合金试样的主要磨损形式为对摩钛合金材料的粘结,TSL试样能够减小磨痕宽度和对摩材料的粘结高度,同时减小对摩球的磨损损失。分析和揭示了TSL试样的减摩润滑机理：摩擦过程中,存储在织构凹槽中的固体润滑剂在摩擦挤压作用下析出,并拖覆在摩擦接触面形成润滑层,拖覆的润滑剂也会被摩擦带走,但凹槽中润滑剂会不断析出补给,从而在摩擦接触面形成连续动态的固体润滑层；织构凹槽同时具有扑捉和存储磨损颗粒的作用,降低摩擦和磨损。
采用仿真的方法研究了振荡热管强化刀具散热的效果。建立了热流密度反求的目标函数并求解获得了加载在刀-屑接触区的热流密度,研究了刀具温度场分布情况,结果表明：振荡热管自冷却刀具能够有效降低刀具的最高切削温度,同时能够缩短刀具达到稳态切削温度的时间。
将微织构自润滑刀具(SLT)、振荡热管自冷却刀具(SCT)、微织构自润滑与振荡热管自冷却双重效用的干切削刀具(SLCT)以及传统硬质合金刀具(CT)进行了车削Ti6A14V的对比试验,研究了微织构自润滑与振荡热管自冷却双重效用的干切削刀具的切削性能。结果表明：SLT和SLCT刀具相比CT刀具能够有效降低三向切削力,减小刀-屑平均摩擦系数,增加切屑卷曲并减小切屑剪切变形；SLT、SCT和SLCT三种刀具相比CT刀具均能够降低切削温度,相同切削条件下,SLCT刀具的切削温度最低；SLT、SCT和SLCT刀具相比CT刀具均能够减轻刀具的磨损,其中以SLCT刀具的磨损最为轻微。
分析和揭示了微织构自润滑与振荡热管自冷却双重效用的干切削刀具改善切削加工的作用机理。一方面,在切削过程中织构凹槽中的固体润滑剂拖覆在前刀面形成固体润滑层,降低了刀-屑摩擦剪切强度和刀-屑实际接触长度,这将有利于降低切削力和切削温度,增加切屑卷曲并减小切屑变形；另一方面,嵌入的振荡热管能够强化刀具的散热,有效降低刀具的切削温度。
The concept of self-lubricating and self-cooling dry cutting tool based on surface texturing and pulsating heat pipe is proposed in this paper. A new micro-texture self-lubricating and pulsating heat pipe self-cooling dry cutting tool has been developed successfully, as well as its tribological behaviors, heat dissipation performance, cutting performance, more over, the self-lubricating and self-cooling mechanisms are studied and analyzed in detail.
Based on the analysis of the mechanism of friction and lubrication in cutting process, the concept and design ideas of micro-texture self-lubricating tool is proposed. Micro-textures are made on the rake face of tool inserts, and solid lubricants are filled into the textured grooves to form micro-texture self-lubricating tools. During cutting process, due to the friction and extrusion of the chip which slides against the tool rake face at high speed, the solid lubricants may be released from the textured grooves and smeared on the tool-chip interface. Then a thin lubricating film, which can be acted to reduce the friction coefficient and adhesion, may be formed between the tool-chip interface. The structure of the micro-textures is studied and optimized. The effect of micro-textures on stress distribution of the cutting tools is analyzed and the appropriate structural parameters of micro-textures are put forward:the micro-textures are with double-elliptic structure, the long diameter and short diameter of the external elliptic are0.8mm and0.6mm respectively, the distance between micro-textures and cutting edge is150μm, the distance between textured grooves is150μm, the width and depth of the textured grooves are50μm and100μm respectively. Molybdenum disulfide solid lubricants(MoS2) are selected as the used lubricating material. The micro-texture self-lubricating tools are fabricated by laser machining.
The concept and design ideas of pulsating heat pipe self-cooling tool is proposed, namely that by the excellent heat transfer performance of the pulsating heat pipe, enhance the dissipation of cutting heat to achieve the self-cooling tools. Based on the temperature environment of cutting process and the structure size of tool inserts, the pulsating heat pipe is designed and the appropriate parameters are put forward:the working fluid is water, the pipe wall material is copper, the outer diameter and inner diameter of the pipe are2mm and1.2mm respectively, the filling rate of working fluid is60%. Four-bend, six-bend and eight-bend pulsating heat pipe self-cooling tools are fabricated by electrical discharge machining.
The effect of surface textures on friction properties of cemented carbide tool material is studied. Dry sliding friction and wear tests against titanium alloy balls were carried out with the smooth surface without solid lubricants (SS), the smooth surface burnished with molybdenum disulfide solid lubricants (SSL), the textured surface without (TS) and with solid lubricants (TSL) for comparison. The results show:the SSL sample can not effectively improve the frictional performance of the cemented carbide, the TS sample has a worse tribological behavior compared with the SS sample, however, only the TSL sample shows the benefit in improving the tribological properties. The average friction coefficient and average friction temperature of the TSL sample are reduced by20～25%and8～15%compared with that of the SS sample respectively. Adhesion of titanium alloy materials on the worn cemented carbide surface is the main wear form, the TSL sample can reduce the width of wear scars on the cemented disks and wear loss of titanium alloy balls. The anti-friction mechanism of the TSL sample is put forward:in friction process, the solid lubricants filled in the textured grooves are released and smeared on the worn surface by frictional extrusion, as a result, forms a dynamic thin lubricating film at the ball-disk interface. Meanwhile, the textured grooves can trap wear debris, which is also benefical to the reduction in friction and wear.
The effect of pulsating heat pipe on cutting heat dissipation is studied by numerical simulation. The heat flux loaded on the tool-chip interface is solved by a method of inverse evaluation, and then the temperature field of cutting tools is analyzed. The results show:the maximum cutting temperatures of the pulsating heat pipe self-lubricating tools are lower than those of the conventional tool, the pulsating heat pipe self-cooling tools can also reduce the time from the beginning of cutting to the steady state of cutting temperature.
Cutting tests on Ti6A14V alloy are carried out with the micro-texture self-lubricating tool(SLT), the pulsating heat pipe self-cooling tool(SCL), the micro-texture self-lubricating and pulsating heat pipe self-cooling tool(SLCT) as well as the conventional cutting tool(CT). The results show:compared with the CT tool, the SLT and SLCT tools can reduce three direction cutting force, friction coefficient at the tool-chip interface and chip thickness ratio, and increase curly degree of the chip. The SLT, SCT and SLCT tools can reduce cutting temperature and tool wear compared with the CT tool, operation with the SLCT tool could obtain the lowest cutting temperature and tool wear.
The mechanism of that the micro-texture self-lubricating and pulsating heat pipe self-cooling dry cutting tool improves the cutting performance is analyzed. On the one hand, during cutting process, the solid lubricants filled in the textured grooves are released and smeared on the tool-chip interface and form a lubricating film, which can reduce the frictional shear strength and tool-chip contact length, as a result, the cutting force, cutting temperature and chip thickness ratio are reduced and the curly degree of the chip is improved. On the other hand, the pulsating heat pipe can enhance the dissipation of cutting heat, as a result, reduce the cutting temperature.
在分析刀具切削的摩擦和润滑机理的基础上,提出了微织构自润滑刀具的设计概念,即：在刀具前刀面的刀-屑接触区加工微织构,并在微织构凹槽中填充固体润滑剂,在切削过程中织构凹槽中的固体润滑剂受摩擦挤压作用拖覆在刀-屑接触界面形成润滑膜,实现刀具的自润滑。建立了微织构自润滑刀具的设计模型,结合微织构对刀具应力分布的影响,确定了微织构自润滑刀具的微织构的最佳结构参数：槽型为双椭圆结构,其外椭圆的长径为0.8mm、短径为0.6mm,织构距切削刃距离L为150μm,凹槽中心间距H为150μm,凹槽宽度B为50μm,槽深为100μm。优选了二硫化钼(MoS2)作为微织构自润滑刀具使用的固体润滑剂。采用激光加工技术制备了微织构自润滑刀具。
将振荡热管冷却技术应用到刀具散热上,提出了振荡热管自冷却刀具的设计概念,即：在刀具中嵌入振荡热管,切削过程中,振荡热管因具有优良的导热性能而能够加快切削区温度的导出,从而实现刀具的自冷却。建立了振荡热管自冷却刀具的设计方法,根据刀具切削的温度环境和刀片的结构尺寸,确定振荡热管自冷却刀具的振荡热管使用的工质为水,管壁材料为铜,管的外径和内径分别为2mm和1.2mm,工质充液率为60%。采用电火花加工技术制备了四弯道、六弯道和八弯道三种振荡热管自冷却刀具。
研究了表面织构对硬质合金刀具材料的摩擦磨损特性的影响。将光滑表面试样(SS)、光滑表面抹覆润滑剂的试样(SSL)、表面织构试样(TS)和填充润滑剂的表面织构试样(TSL)与钛合金球对摩进行了对比干摩擦试验,结果表明：与SS试样相比,SSL试样并不能改善硬质合金的摩擦磨损性能,TS试样的摩擦磨损状况更为恶劣,TSL试样能够有效改善硬质合金的摩擦磨损性能；TSL试样相比SS试样降低平均摩擦系数达20-25%,降低摩擦温度达8-15%；硬质合金试样的主要磨损形式为对摩钛合金材料的粘结,TSL试样能够减小磨痕宽度和对摩材料的粘结高度,同时减小对摩球的磨损损失。分析和揭示了TSL试样的减摩润滑机理：摩擦过程中,存储在织构凹槽中的固体润滑剂在摩擦挤压作用下析出,并拖覆在摩擦接触面形成润滑层,拖覆的润滑剂也会被摩擦带走,但凹槽中润滑剂会不断析出补给,从而在摩擦接触面形成连续动态的固体润滑层；织构凹槽同时具有扑捉和存储磨损颗粒的作用,降低摩擦和磨损。
采用仿真的方法研究了振荡热管强化刀具散热的效果。建立了热流密度反求的目标函数并求解获得了加载在刀-屑接触区的热流密度,研究了刀具温度场分布情况,结果表明：振荡热管自冷却刀具能够有效降低刀具的最高切削温度,同时能够缩短刀具达到稳态切削温度的时间。
将微织构自润滑刀具(SLT)、振荡热管自冷却刀具(SCT)、微织构自润滑与振荡热管自冷却双重效用的干切削刀具(SLCT)以及传统硬质合金刀具(CT)进行了车削Ti6A14V的对比试验,研究了微织构自润滑与振荡热管自冷却双重效用的干切削刀具的切削性能。结果表明：SLT和SLCT刀具相比CT刀具能够有效降低三向切削力,减小刀-屑平均摩擦系数,增加切屑卷曲并减小切屑剪切变形；SLT、SCT和SLCT三种刀具相比CT刀具均能够降低切削温度,相同切削条件下,SLCT刀具的切削温度最低；SLT、SCT和SLCT刀具相比CT刀具均能够减轻刀具的磨损,其中以SLCT刀具的磨损最为轻微。
分析和揭示了微织构自润滑与振荡热管自冷却双重效用的干切削刀具改善切削加工的作用机理。一方面,在切削过程中织构凹槽中的固体润滑剂拖覆在前刀面形成固体润滑层,降低了刀-屑摩擦剪切强度和刀-屑实际接触长度,这将有利于降低切削力和切削温度,增加切屑卷曲并减小切屑变形；另一方面,嵌入的振荡热管能够强化刀具的散热,有效降低刀具的切削温度。
The concept of self-lubricating and self-cooling dry cutting tool based on surface texturing and pulsating heat pipe is proposed in this paper. A new micro-texture self-lubricating and pulsating heat pipe self-cooling dry cutting tool has been developed successfully, as well as its tribological behaviors, heat dissipation performance, cutting performance, more over, the self-lubricating and self-cooling mechanisms are studied and analyzed in detail.
Based on the analysis of the mechanism of friction and lubrication in cutting process, the concept and design ideas of micro-texture self-lubricating tool is proposed. Micro-textures are made on the rake face of tool inserts, and solid lubricants are filled into the textured grooves to form micro-texture self-lubricating tools. During cutting process, due to the friction and extrusion of the chip which slides against the tool rake face at high speed, the solid lubricants may be released from the textured grooves and smeared on the tool-chip interface. Then a thin lubricating film, which can be acted to reduce the friction coefficient and adhesion, may be formed between the tool-chip interface. The structure of the micro-textures is studied and optimized. The effect of micro-textures on stress distribution of the cutting tools is analyzed and the appropriate structural parameters of micro-textures are put forward:the micro-textures are with double-elliptic structure, the long diameter and short diameter of the external elliptic are0.8mm and0.6mm respectively, the distance between micro-textures and cutting edge is150μm, the distance between textured grooves is150μm, the width and depth of the textured grooves are50μm and100μm respectively. Molybdenum disulfide solid lubricants(MoS2) are selected as the used lubricating material. The micro-texture self-lubricating tools are fabricated by laser machining.
The concept and design ideas of pulsating heat pipe self-cooling tool is proposed, namely that by the excellent heat transfer performance of the pulsating heat pipe, enhance the dissipation of cutting heat to achieve the self-cooling tools. Based on the temperature environment of cutting process and the structure size of tool inserts, the pulsating heat pipe is designed and the appropriate parameters are put forward:the working fluid is water, the pipe wall material is copper, the outer diameter and inner diameter of the pipe are2mm and1.2mm respectively, the filling rate of working fluid is60%. Four-bend, six-bend and eight-bend pulsating heat pipe self-cooling tools are fabricated by electrical discharge machining.
The effect of surface textures on friction properties of cemented carbide tool material is studied. Dry sliding friction and wear tests against titanium alloy balls were carried out with the smooth surface without solid lubricants (SS), the smooth surface burnished with molybdenum disulfide solid lubricants (SSL), the textured surface without (TS) and with solid lubricants (TSL) for comparison. The results show:the SSL sample can not effectively improve the frictional performance of the cemented carbide, the TS sample has a worse tribological behavior compared with the SS sample, however, only the TSL sample shows the benefit in improving the tribological properties. The average friction coefficient and average friction temperature of the TSL sample are reduced by20～25%and8～15%compared with that of the SS sample respectively. Adhesion of titanium alloy materials on the worn cemented carbide surface is the main wear form, the TSL sample can reduce the width of wear scars on the cemented disks and wear loss of titanium alloy balls. The anti-friction mechanism of the TSL sample is put forward:in friction process, the solid lubricants filled in the textured grooves are released and smeared on the worn surface by frictional extrusion, as a result, forms a dynamic thin lubricating film at the ball-disk interface. Meanwhile, the textured grooves can trap wear debris, which is also benefical to the reduction in friction and wear.
The effect of pulsating heat pipe on cutting heat dissipation is studied by numerical simulation. The heat flux loaded on the tool-chip interface is solved by a method of inverse evaluation, and then the temperature field of cutting tools is analyzed. The results show:the maximum cutting temperatures of the pulsating heat pipe self-lubricating tools are lower than those of the conventional tool, the pulsating heat pipe self-cooling tools can also reduce the time from the beginning of cutting to the steady state of cutting temperature.
Cutting tests on Ti6A14V alloy are carried out with the micro-texture self-lubricating tool(SLT), the pulsating heat pipe self-cooling tool(SCL), the micro-texture self-lubricating and pulsating heat pipe self-cooling tool(SLCT) as well as the conventional cutting tool(CT). The results show:compared with the CT tool, the SLT and SLCT tools can reduce three direction cutting force, friction coefficient at the tool-chip interface and chip thickness ratio, and increase curly degree of the chip. The SLT, SCT and SLCT tools can reduce cutting temperature and tool wear compared with the CT tool, operation with the SLCT tool could obtain the lowest cutting temperature and tool wear.
The mechanism of that the micro-texture self-lubricating and pulsating heat pipe self-cooling dry cutting tool improves the cutting performance is analyzed. On the one hand, during cutting process, the solid lubricants filled in the textured grooves are released and smeared on the tool-chip interface and form a lubricating film, which can reduce the frictional shear strength and tool-chip contact length, as a result, the cutting force, cutting temperature and chip thickness ratio are reduced and the curly degree of the chip is improved. On the other hand, the pulsating heat pipe can enhance the dissipation of cutting heat, as a result, reduce the cutting temperature.
引文
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