基于钛合金高速铣削刀具失效演变的硬质合金涂层刀具设计与制造
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摘要
由于密度小、强度／重量比高、高温稳定性好以及耐腐蚀性好等特点,钛合金被广泛应用于航空航天领域。但因钛合金低的导热性、高的化学活性以及弹性模量小等特点,使其切削加工性差、刀具寿命低,被公认为难加工材料,这限制了切削速度和生产率的提高。本文以钛合金高速铣削刀具失效演变对硬质合金涂层刀具性能的要求为指导和依据,以高性能硬质合金刀具材料设计、刀具结构设计和刀具涂层设计为核心,对硬质合金涂层刀具设计理论与方法进行了深入研究和探讨,最终研制成功适用于钛合金型面侧壁铣削的整体硬质合金涂层立铣刀,并研究了其切削性能。
对高速铣削切屑形貌进行了多视角表征,研究了高速铣削钛合金Ti-6Al-4V时切屑自由表面、背面和纵截面的形貌特征及其参数变化规律；通过锯齿形切屑剪切带微观组织分析,揭示了锯齿形切屑形成的绝热剪切机理(热塑性剪切失稳),发现了切屑背面层组织的衍射峰宽化效应。研究了不同切削条件下铣削Ti-6Al-4V时的刀具失效演变过程,以及切削力和切削温度的变化规律,分析了刀具失效演变过程中刀具不同部位(前、后刀面)和不同失效阶段的刀具失效形貌。揭示了高速切削热—力—化学多场强作用下刀具由微观损伤到宏观失效的演变机制,刀具失效机理主要为涂层剥落、磨粒磨损、粘结磨损、氧化磨损、扩散磨损和热—机械疲劳的综合作用。从而对刀具性能提出了以下要求：刀具材料和涂层材料应与钛合金具有良好的化学相容性；刀具材料应具有较好的耐磨性和抗疲劳性能；应提高涂层与刀具基体的界面结合力,以避免涂层过早剥落,采用耐高温的涂层材料以保护刀具基体。
基于钛合金高速铣削刀具失效演变对刀具材料的性能要求,通过研究硬质合金刀具材料与工件材料的化学相容性和摩擦学匹配性,并建立WC-Co硬质合金刀具材料微观结构参数(Co含量、平均晶粒度和WC晶粒邻接度等)与宏观性能之间的关系,从而对钛合金高速铣削用硬质合金刀具材料进行了设计。结果表明,Co含量为10wt.%的亚微细晶粒硬质合金(平均晶粒度为0.6-0.8μm)盘与钛合金球对磨时,可获得较小的摩擦系数和较好的耐磨性。基于UG平台二次开发了整体硬质合金立铣刀参数化设计和二维图绘制及生成软件,实现了对整体立铣刀的计算机辅助快速设计。利用整体硬质合金立铣刀切削钛合金工件材料的三维铣削有限元仿真,以低的切削力和切削温度为目标,优化了螺旋角、刀具前角和刀齿数等刀具结构和刀刃儿何参数。采用直径20mm的整体硬质合金平头立铣刀铣削钛合金时,主要刀具结构和刀刃几何参数优化结果为：芯部直径为12mm、齿数为4齿、螺旋角为44°以及侧刃前角为9°。
烧结制备并测试表征了不同Co含量和晶粒尺寸的硬质合金刀具材料,研究了其制备工艺、微观结构和力学性能,以及抗机械疲劳性能,验证了材料设计的合理性。硬质合金断裂主要为脆性断裂,断裂方式主要为沿晶断裂和少数WC晶粒的穿晶断裂的混合模式。晶粒细化提高了硬质合金材料硬度和横向断裂强度,但以降低断裂韧度为代价；高Co含量硬质合金的横向断裂强度和断裂切度有所提高,但硬度较低。采和三点弯曲试样研究了硬质合金刀具材料的机械疲劳行为,结果表明,疲劳断裂通常起源于缺口尖端的不均匀缺陷,如微孔洞或粗大WC晶粒处,低Co含量硬质合金由于韧性较差,其疲劳行为主要取决于横向断裂强度,高Co含量硬质合金的断裂韧度是影响其抗疲劳性能的主要因素。
为减少涂层在刀具失效过程中的剥落现象,提出硬质合金刀具涂层设计方法,基于复合涂层性能参数等效理论建立了复合涂层沉积过程残余热应力产生模型,并将计算结果与有限元仿真结果进行了对比验证,为难加工材料高速切削刀具涂层选择与设计提供理论依据。刀具涂层厚度选择3μm时,在涂层沉积过程中可获得较小的残余热应力。研究了CrN、TiN、TiAlN、AlTiN和AlCrN五种涂层的硬质合金盘与钛合金球的摩擦学匹配特性。结果表明,TiAlN涂层与钛合金对磨时可获得较小的摩擦系数和较好的耐磨性。提出了高速铣削刀具涂层设计的基本原则,为高速铣削刀具涂层的设计提供了依据。
研究了所研制的整体硬质合金立铣刀高速铣削钛合金切切削性能,并将其与某同类刀具进行了切削对比试验,其切削力低于该同类刀具,切屑形成和刀具寿命都优于该同类刀具。
Because of the low density, the high strength-to-weight ratio, the favourable stability maintained at elevated temperature, and the exceptional resistance to corrosion, titanium alloys are used extensively in aerospace industry. However, titanium alloys are known as difficult-to-machine materials, due to their several inherent properties, such as low thermal conductivity, high chemical reactivity, and low Young's modulus. The cutting speed and productivity in machining titanium alloys are adversely restricted because of the low machinability and tool life. With the property requirements of tool failure evolution for coated carbide tools in high speed milling of difficult-to-machine materials, such as titanium alloys, as the guidance and basis, and with the carbide tool material design, tool structure design, and tool coating design as the core, the design theory and methods of coated carbide tools were in-depth investigated and discussed. Finally, the solid carbide coated end mill applied to sidewall surface milling of titanium alloy was successfully developed and its cutting performance was investigated.
The multi-view characterization of the chips, which includes free surface, back surface, and cross-sectional surface, was carried out in high-speed milling of Ti-6A1-4V alloy. The variation of characteristics and parameters of chip morphologies were investigated. The results indicated that chip formation takes place by the mechanism of catastrophic thermoplastic shear from the observation of the shear bands using metallurgical analyses of microstructure. There exists the broadening of the diffraction peaks in the back surface of chips. Progressive tool failure processes under different cutting conditions were discussed. The variations of cutting forces components and transient infrared temperature during the machining processes were investigated. The variations of tool failure morphologies and tool failure mechanisms in different positions (rake and flank faces) and different failure stages of the progressive tool failure processes were discussed. The evolution of tool micro-damage to macroscopic failure under the multi-strong thermal-mechanical-chemical fields in high-speed milling was revealed. Tool failure mechanisms were synergistic interaction among coating delamination, abrasive wear, adhesive wear, oxidation wear, diffusion wear and thermal-mechanical fatigue wear. The following requirements, such as good matchability between tool material, coating material and titanium alloy, good wear resistance and fatigue properties for tool material, high interfacial adhesion between coatings and tool substrate, and coating material bearing high temperature to protect tool substrate, are proposed.
With regard to the property requirements of progressive tool failure for coated carbide tools in high speed milling, the chemical and tribological matchability of carbide tool material and workpiece material were investigated. The relationships between microstructural parameters (Co content, mean grain size, and WC contiguity) and macroscopic properties were built up. The carbide tool material used in high-speed milling of titanium alloy was selected and designed. The results indicated that the sub-micro fine cemented carbide with10wt.%Co binder (WC grain size in0.6～0.8μm) revealed the smallest friction coefficient and the best wear resistance when sliding against tatinium alloy. The parameterized design software of solid carbide end mill was secondary developed based on UG platform. The software can map or generate two-dimensional engineering drawings, and implement the computer aided rapid design of solid end mills. Three-dimensional finite element simulation of solid carbide end mills in machining titanium alloy was conducted by using Deform-3D. The geometric parameters of the tool structure and cutting edge, such as helix angle, rake angle, and number of teeth, were optimized with low cutting force and cutting temperature as the target. The optimized results are a12mm inner diameter,4teeth, a44°helix angle, a9°side rake angle.
The carbide tool materials with various Co content and grain size was sintered, prepared, tested and characterized. The preparation processes, microstructure, mechanical properties, and mechanical fatigue behaviours of carbide tool materials were investigated to verify the reasonableness of material design. The fracture mode can be described as brittle fracture, especially the mixed-mode of intergranular fracture and transgranular fracture of aggregates of WC grains. Grain refinement improves the hardness and transverse rupture strength of carbide tool materials at the expense of reducing fracture toughness. High Co contents of carbide tool materials increase the transverse rupture strength and fracture toughness at the expense of low hardness. The three-point bending fatigue characteristics of WC-Co cemented carbides were investigated using three-point bending specimens. The fatigue fracture typically originates from inhomogeneities or defects such as micropores or aggregates of WC grains near the notch tip. Transverse rupture strength dominated the fatigue behaviour of carbides with low Co content, whilst the fatigue behaviour of carbides with high Co content was determined by fracture toughness.
A theoretical method was proposed for the coating design of carbide tools, in order to reduce the possibility of coating delamination in the tool failure processes. The thermal residual stresses of multi-layered coatings were modeled based on equivalent parameters of coating properties, and the calculated results were verified with finite element simulation. This provides theorical basis for the selection and design of coatings of cutting tools in high-speed machining. The resluts show that coatings with a thickness of3μm will produce considerably low thermal residual stresses in the coating deposition process. Dry siding ball-on-disk wear tests of CrN, TiN, TiAIN, AlTiN and AlCrN coatings on flat WC-Co cemented carbide substrate against titanium balls were conducted to evaluate the tribological matchability of tool coatings and workpiece material. TiAIN is strongly recommended as coating of carbide tools when machining titanium alloys due to the lowest friction coefficient and the best wear resistance when sliding against Ti-6A1-4V. Based on the evaluations of matchability of tool substrate and tool coatings, as well as that of tool coatings and workpiece material, the basic principles of tool coating design in high-speed milling were proposed, laying the foundation of the coating design of cutting tools.
Cutting performance of the developed solid carbide end mill in high-speed milling of titanium alloy was investigated, comparing with that of a similar end mill. The developed end mill exhibited smaller cutting forces, better chip formation, and longer tool life than the similar tool.
对高速铣削切屑形貌进行了多视角表征,研究了高速铣削钛合金Ti-6Al-4V时切屑自由表面、背面和纵截面的形貌特征及其参数变化规律；通过锯齿形切屑剪切带微观组织分析,揭示了锯齿形切屑形成的绝热剪切机理(热塑性剪切失稳),发现了切屑背面层组织的衍射峰宽化效应。研究了不同切削条件下铣削Ti-6Al-4V时的刀具失效演变过程,以及切削力和切削温度的变化规律,分析了刀具失效演变过程中刀具不同部位(前、后刀面)和不同失效阶段的刀具失效形貌。揭示了高速切削热—力—化学多场强作用下刀具由微观损伤到宏观失效的演变机制,刀具失效机理主要为涂层剥落、磨粒磨损、粘结磨损、氧化磨损、扩散磨损和热—机械疲劳的综合作用。从而对刀具性能提出了以下要求：刀具材料和涂层材料应与钛合金具有良好的化学相容性；刀具材料应具有较好的耐磨性和抗疲劳性能；应提高涂层与刀具基体的界面结合力,以避免涂层过早剥落,采用耐高温的涂层材料以保护刀具基体。
基于钛合金高速铣削刀具失效演变对刀具材料的性能要求,通过研究硬质合金刀具材料与工件材料的化学相容性和摩擦学匹配性,并建立WC-Co硬质合金刀具材料微观结构参数(Co含量、平均晶粒度和WC晶粒邻接度等)与宏观性能之间的关系,从而对钛合金高速铣削用硬质合金刀具材料进行了设计。结果表明,Co含量为10wt.%的亚微细晶粒硬质合金(平均晶粒度为0.6-0.8μm)盘与钛合金球对磨时,可获得较小的摩擦系数和较好的耐磨性。基于UG平台二次开发了整体硬质合金立铣刀参数化设计和二维图绘制及生成软件,实现了对整体立铣刀的计算机辅助快速设计。利用整体硬质合金立铣刀切削钛合金工件材料的三维铣削有限元仿真,以低的切削力和切削温度为目标,优化了螺旋角、刀具前角和刀齿数等刀具结构和刀刃儿何参数。采用直径20mm的整体硬质合金平头立铣刀铣削钛合金时,主要刀具结构和刀刃几何参数优化结果为：芯部直径为12mm、齿数为4齿、螺旋角为44°以及侧刃前角为9°。
烧结制备并测试表征了不同Co含量和晶粒尺寸的硬质合金刀具材料,研究了其制备工艺、微观结构和力学性能,以及抗机械疲劳性能,验证了材料设计的合理性。硬质合金断裂主要为脆性断裂,断裂方式主要为沿晶断裂和少数WC晶粒的穿晶断裂的混合模式。晶粒细化提高了硬质合金材料硬度和横向断裂强度,但以降低断裂韧度为代价；高Co含量硬质合金的横向断裂强度和断裂切度有所提高,但硬度较低。采和三点弯曲试样研究了硬质合金刀具材料的机械疲劳行为,结果表明,疲劳断裂通常起源于缺口尖端的不均匀缺陷,如微孔洞或粗大WC晶粒处,低Co含量硬质合金由于韧性较差,其疲劳行为主要取决于横向断裂强度,高Co含量硬质合金的断裂韧度是影响其抗疲劳性能的主要因素。
为减少涂层在刀具失效过程中的剥落现象,提出硬质合金刀具涂层设计方法,基于复合涂层性能参数等效理论建立了复合涂层沉积过程残余热应力产生模型,并将计算结果与有限元仿真结果进行了对比验证,为难加工材料高速切削刀具涂层选择与设计提供理论依据。刀具涂层厚度选择3μm时,在涂层沉积过程中可获得较小的残余热应力。研究了CrN、TiN、TiAlN、AlTiN和AlCrN五种涂层的硬质合金盘与钛合金球的摩擦学匹配特性。结果表明,TiAlN涂层与钛合金对磨时可获得较小的摩擦系数和较好的耐磨性。提出了高速铣削刀具涂层设计的基本原则,为高速铣削刀具涂层的设计提供了依据。
研究了所研制的整体硬质合金立铣刀高速铣削钛合金切切削性能,并将其与某同类刀具进行了切削对比试验,其切削力低于该同类刀具,切屑形成和刀具寿命都优于该同类刀具。
Because of the low density, the high strength-to-weight ratio, the favourable stability maintained at elevated temperature, and the exceptional resistance to corrosion, titanium alloys are used extensively in aerospace industry. However, titanium alloys are known as difficult-to-machine materials, due to their several inherent properties, such as low thermal conductivity, high chemical reactivity, and low Young's modulus. The cutting speed and productivity in machining titanium alloys are adversely restricted because of the low machinability and tool life. With the property requirements of tool failure evolution for coated carbide tools in high speed milling of difficult-to-machine materials, such as titanium alloys, as the guidance and basis, and with the carbide tool material design, tool structure design, and tool coating design as the core, the design theory and methods of coated carbide tools were in-depth investigated and discussed. Finally, the solid carbide coated end mill applied to sidewall surface milling of titanium alloy was successfully developed and its cutting performance was investigated.
The multi-view characterization of the chips, which includes free surface, back surface, and cross-sectional surface, was carried out in high-speed milling of Ti-6A1-4V alloy. The variation of characteristics and parameters of chip morphologies were investigated. The results indicated that chip formation takes place by the mechanism of catastrophic thermoplastic shear from the observation of the shear bands using metallurgical analyses of microstructure. There exists the broadening of the diffraction peaks in the back surface of chips. Progressive tool failure processes under different cutting conditions were discussed. The variations of cutting forces components and transient infrared temperature during the machining processes were investigated. The variations of tool failure morphologies and tool failure mechanisms in different positions (rake and flank faces) and different failure stages of the progressive tool failure processes were discussed. The evolution of tool micro-damage to macroscopic failure under the multi-strong thermal-mechanical-chemical fields in high-speed milling was revealed. Tool failure mechanisms were synergistic interaction among coating delamination, abrasive wear, adhesive wear, oxidation wear, diffusion wear and thermal-mechanical fatigue wear. The following requirements, such as good matchability between tool material, coating material and titanium alloy, good wear resistance and fatigue properties for tool material, high interfacial adhesion between coatings and tool substrate, and coating material bearing high temperature to protect tool substrate, are proposed.
With regard to the property requirements of progressive tool failure for coated carbide tools in high speed milling, the chemical and tribological matchability of carbide tool material and workpiece material were investigated. The relationships between microstructural parameters (Co content, mean grain size, and WC contiguity) and macroscopic properties were built up. The carbide tool material used in high-speed milling of titanium alloy was selected and designed. The results indicated that the sub-micro fine cemented carbide with10wt.%Co binder (WC grain size in0.6～0.8μm) revealed the smallest friction coefficient and the best wear resistance when sliding against tatinium alloy. The parameterized design software of solid carbide end mill was secondary developed based on UG platform. The software can map or generate two-dimensional engineering drawings, and implement the computer aided rapid design of solid end mills. Three-dimensional finite element simulation of solid carbide end mills in machining titanium alloy was conducted by using Deform-3D. The geometric parameters of the tool structure and cutting edge, such as helix angle, rake angle, and number of teeth, were optimized with low cutting force and cutting temperature as the target. The optimized results are a12mm inner diameter,4teeth, a44°helix angle, a9°side rake angle.
The carbide tool materials with various Co content and grain size was sintered, prepared, tested and characterized. The preparation processes, microstructure, mechanical properties, and mechanical fatigue behaviours of carbide tool materials were investigated to verify the reasonableness of material design. The fracture mode can be described as brittle fracture, especially the mixed-mode of intergranular fracture and transgranular fracture of aggregates of WC grains. Grain refinement improves the hardness and transverse rupture strength of carbide tool materials at the expense of reducing fracture toughness. High Co contents of carbide tool materials increase the transverse rupture strength and fracture toughness at the expense of low hardness. The three-point bending fatigue characteristics of WC-Co cemented carbides were investigated using three-point bending specimens. The fatigue fracture typically originates from inhomogeneities or defects such as micropores or aggregates of WC grains near the notch tip. Transverse rupture strength dominated the fatigue behaviour of carbides with low Co content, whilst the fatigue behaviour of carbides with high Co content was determined by fracture toughness.
A theoretical method was proposed for the coating design of carbide tools, in order to reduce the possibility of coating delamination in the tool failure processes. The thermal residual stresses of multi-layered coatings were modeled based on equivalent parameters of coating properties, and the calculated results were verified with finite element simulation. This provides theorical basis for the selection and design of coatings of cutting tools in high-speed machining. The resluts show that coatings with a thickness of3μm will produce considerably low thermal residual stresses in the coating deposition process. Dry siding ball-on-disk wear tests of CrN, TiN, TiAIN, AlTiN and AlCrN coatings on flat WC-Co cemented carbide substrate against titanium balls were conducted to evaluate the tribological matchability of tool coatings and workpiece material. TiAIN is strongly recommended as coating of carbide tools when machining titanium alloys due to the lowest friction coefficient and the best wear resistance when sliding against Ti-6A1-4V. Based on the evaluations of matchability of tool substrate and tool coatings, as well as that of tool coatings and workpiece material, the basic principles of tool coating design in high-speed milling were proposed, laying the foundation of the coating design of cutting tools.
Cutting performance of the developed solid carbide end mill in high-speed milling of titanium alloy was investigated, comparing with that of a similar end mill. The developed end mill exhibited smaller cutting forces, better chip formation, and longer tool life than the similar tool.
引文
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