高铬铸铁切削加工过程有限元模拟仿真研究
|
摘要
高铬铸铁作为一种优良的耐磨材料，被越来越广泛地应用于制造耐磨零件。高铬铸铁不仅抗磨能力优良而且还具备一定的冲击韧性，这主要是由其特殊的金相组织决定的，然而也正是由于这种特殊的金相组织使得高铬铸铁在切削加工过程中面临刀具磨损严重、加工效率低下等一系列问题。高铬铸铁的切削加工问题如果得不到很好的解决，势必会限制其应用范围。
针对高铬铸铁在切削加工过程中面临的一系列问题，本研究将有限元法应用于解决高铬铸铁的切削加工问题。
本研究将主要从以下几方面着手：
（1）建立了描述高铬铸铁本构关系的Johnson-Cook本构模型；
（2）对切削加工过程模拟仿真涉及到的关键技术一一进行阐述；
（3）利用ABAQUS有限元分析软件模拟仿真高铬铸铁的切削加工过程，并对模拟仿真结果是否出现沙漏现象进行验证；
（4）在没有出现沙漏现象的前提下，根据模拟仿真结果，分析高铬铸铁切削加工过程中与刀具磨损密切相关的切削力和切削热在不同刀具前角和切削用量下的变化情况。
（5）优化选择切削加工高铬铸铁的刀具前角和切削用量，以达到延长刀具寿命、降低加工成本的目的。
本研究成果可以在一定程度上改善高铬铸铁的切削加工性，对高铬铸铁在实际加工过程中刀具前角和切削用量的选择具有一定的理论指导意义。
As an excellent wear resistant material,high chromium cast iron has been being utilizedto manufacture wear parts increasingly. High chromium cast iron is not only wear resistant,butalso of high impact toughness, and it is all determined by its unique metallographicstructure.However, the very metallographic structure results in a series of problems in highchromium cast iron cutting process, such as cutter wear,low machining efficiency and so on.Ifthe cutting problems of high chromium cast iron is not well solved, it certainly will restrict therange of application.
This research applies FEM to solving the cutting problem of high chromium cast iron.
This research will proceed form the following aspects:
(1) Modeling Johnson-Cook constructive model describing the constructive relation ofhigh chromium cast iron;
(2) Demonstrating the key techniques of simulation of cutting process;
(3) Modeling cutting process of high chromium cast iron by FEM software ABAQUS,and checking whether hourglass phenomenon emerges;
(4) Under the premise that the hourglass phenomenon doesn’t emerge, according to theresults of simulation, analyzing the variation of cutting force and cutting heat, whichhave something to do with cutter wear, under different rake angles and cuttingspecifications;
(5) In order to extend service life of cutter when high chromium cast iron iscutting,optimizing rake angles and cutting specification.
This research achievement improve the capacity of high chromium cast iron to someextent,and provide the guidance of optimizing rake angles and cutting specification to highchromium cast iron machining in theory.
针对高铬铸铁在切削加工过程中面临的一系列问题，本研究将有限元法应用于解决高铬铸铁的切削加工问题。
本研究将主要从以下几方面着手：
（1）建立了描述高铬铸铁本构关系的Johnson-Cook本构模型；
（2）对切削加工过程模拟仿真涉及到的关键技术一一进行阐述；
（3）利用ABAQUS有限元分析软件模拟仿真高铬铸铁的切削加工过程，并对模拟仿真结果是否出现沙漏现象进行验证；
（4）在没有出现沙漏现象的前提下，根据模拟仿真结果，分析高铬铸铁切削加工过程中与刀具磨损密切相关的切削力和切削热在不同刀具前角和切削用量下的变化情况。
（5）优化选择切削加工高铬铸铁的刀具前角和切削用量，以达到延长刀具寿命、降低加工成本的目的。
本研究成果可以在一定程度上改善高铬铸铁的切削加工性，对高铬铸铁在实际加工过程中刀具前角和切削用量的选择具有一定的理论指导意义。
As an excellent wear resistant material,high chromium cast iron has been being utilizedto manufacture wear parts increasingly. High chromium cast iron is not only wear resistant,butalso of high impact toughness, and it is all determined by its unique metallographicstructure.However, the very metallographic structure results in a series of problems in highchromium cast iron cutting process, such as cutter wear,low machining efficiency and so on.Ifthe cutting problems of high chromium cast iron is not well solved, it certainly will restrict therange of application.
This research applies FEM to solving the cutting problem of high chromium cast iron.
This research will proceed form the following aspects:
(1) Modeling Johnson-Cook constructive model describing the constructive relation ofhigh chromium cast iron;
(2) Demonstrating the key techniques of simulation of cutting process;
(3) Modeling cutting process of high chromium cast iron by FEM software ABAQUS,and checking whether hourglass phenomenon emerges;
(4) Under the premise that the hourglass phenomenon doesn’t emerge, according to theresults of simulation, analyzing the variation of cutting force and cutting heat, whichhave something to do with cutter wear, under different rake angles and cuttingspecifications;
(5) In order to extend service life of cutter when high chromium cast iron iscutting,optimizing rake angles and cutting specification.
This research achievement improve the capacity of high chromium cast iron to someextent,and provide the guidance of optimizing rake angles and cutting specification to highchromium cast iron machining in theory.
引文
[1]孙家枢.金属的磨损.北京:冶金工业出版社，1992:1-1.
[2]郝石坚.高铬耐磨铸铁.北京:煤炭工业出版社，1993:1-1，287-293，77-78.
[3]陈璟琚，卿上胜等.合金高铬铸铁及其应用.北京:冶金工业出版社，1999:1-1，11-12.
[4]太原市金属切削刀具协会.金属切削实用刀具技术.第二版.北京:机械工业出版社，2002:216-221.
[5]齐笑冰，李卫等.GB/T，8263-1999.抗磨白口铸铁件.北京:中国标准出版社，2000.
[6]汤道华.Al2O3+TiC混合陶瓷刀具加工高铬铸铁辊的实践.江苏冶金.2002，30.3:40-41.
[7]朱正芳.高铬白口铸铁的切削试验.水利电力机械.1984、2:29-32.
[8]林学贤.氮化硅刀具加工高铬白口铁的试验.机械工艺师.1993、2:7-9.
[9]王国顺，戴锦春等.陶瓷刀具切削高铬铸铁切削用量的优化计算.新技术新工艺.2001、4:12-14.
[10]朱从容，王魄.PCBN刀具在加工高铬白口铸铁中的应用.精密制造与自动化.2008、2:60-62.
[11]俞汉清，陈金德.金属塑性成型原理.北京:机械工业出版社,2008:260-261.
[12]庄茁，由小川等.基于ABAQUS的有限元分析和应用.北京:清华大学出版社,2009:6-7.
[13]朱文明.高速切削Ti6Al4V切屑形成仿真研究.硕士学位论文.南京:南京航空航天大学，2007.
[14]邓文君，夏伟等.有限元法在切削加工过程分析中的应用.工具技术.2004,38.11:20-26.
[15] Zienkiewicz O.C.Analysis of the mechanism of orthogonal machining by the finiteelement method.Japan Soc.Prec.Eng.1971,37.7:503-508.
[16] Shirakashi T,Usui E.Simulation analysis of orthogonal metal cutting process.JapanSoc.Prec.Eng.1976,42.5:340-345.
[17] Iwata K,Osakada K,Terasaka Y.Process modeling of orthogonal cutting by therigid-plastic finite element method.Eng.Mater.Technol.1984,106:132-138.
[18] Maekawa K,Maeda M.Simulation analysis of three-dimensional continuous chipformation processes.FEM formulation and a few results.JapanSoc.Prec.Eng.1993,59.11:1827-1833.
[19] Ueda K,Manabe K amd Nozaki S.Rigid-plastic FEM of three-dimensional cuttingmechanism. simulation of plain milling process. Japan Soc.Prec.Eng.1996,62.4:526-531.
[20]刘成文.金属切削加工过程的有限元分析.硕士学位论文.杭州:浙江大学，2002.
[21]于贻鹏.金属切削过程的有限元仿真研究.硕士学位论文.大连:大连理工大学，2005.
[22]刘胜.钛合金正交切削的温度场和切削仿真与试验研究.硕士学位论文.南京:南京航空航天大学，2007.
[23]白万金.航空薄壁件精密铣削加工变形的预测理论及方法研究.博士学位论文.杭州:浙江大学，2008.
[24]房志良，杜学铭等.高铬铸铁抗泥沙磨损性能实验研究.航海工程.2007，36.5:35-37.
[25]甘宅平.高铬铸铁组织及元素分布的研究.钢铁研究.2003、4:41-42.
[26] Maratray F，Poulalion.Austenite Retention in High Cr White Iron.AFSTrans.1982:795-804.
[27]郝石坚.现代铸铁学.第二版.北京:冶金工业出版社,2009:248-255.
[28]郑中甫，孟祥东等.碳含量对高铬铸铁性能的影响.热加工工艺.2007,36.9:38-40.
[29]方亮，饶启昌等.铬系白口铸铁的磨损与断裂特性.西安交通大学学报.1987,21.6:12-18.
[30]陈德华.热处理与高铬铸铁的韧性.硕士学位论文.福州:福州大学，2002.
[31] W.L.Guesser，彭规锦等.铌在高铬铸铁中的应用.铸造.1987、2:41-42.
[32]刘少平，苏丹.钒、钛对高铬铸铁中碳化物形态及耐磨性的影响.热加工工艺.2006,35.1:30-31.
[33]谈淑咏.热处理对高铬铸铁组织和性能的影响.盐城工学院学报(自然科学版).2008,21.1:35-36，46-46，56-56.
[34]阮景奎.汽车覆盖件模具高速切削加工过程的数值模拟与关键工艺技术研究.博士学位论文.杭州:浙江大学，2007.
[35]胡昌明.镁铝合金（MB2）的动态力学性能研究.硕士学位论文.合肥:中国科学技术大学，2003.
[36]刘旭红，黄西成等.强动载荷下金属材料塑性变形本构模型评述.力学进展.2007,37.3:361-374.
[37] Johson G R ,Cook W H. A constitutive model and data for metals subjected to largestrains，high strain rates and high temperatures.Proceedings of the Seventh InternationalSymposium on Ballistics.1983:541-547.
[38] A.S. Milani, W.Dabboussi, J.A.Nemes. An improved multi-objective identificationof Johnson–Cook material parameters. International Journal of ImpactEngineering.2009,36:294-302.
[39]梁文杰.硬态切削过程的有限元仿真.硕士学位论文.哈尔滨:哈尔滨理工大学，2005.
[40]董辉跃.航空整体结构件加工过程的数值仿真.博士学位论文.杭州:浙江大学，2004.
[41] KomvoPoulos F K，Erpenbeek S A.Modeling of orthogonal metal cutting.Journal ofengineering for industry.1991，113.3:253-267
[42] Carroll J T，Strenkowski J S.Finite element models orthogonal cutting withapplication single point diamond turning.International Journal of MechanicalScience.1988,30.11:899-920.
[43] Liangchi Zhang. On the separation criteria in the simulation of orthogonal metalcutting using the finite element method.1999,89:273-278.
[44]陈志刚.金属切削过程及内圆磨削过程有限元仿真.硕士学位论文.湘潭:湘潭大学，2007.
[45] Guoqin Shi, Xiaomin Deng, Chandrakanth Shet. A finite element study of the effectof friction in orthogonal metal cutting. Finite Elements in Analysis andDesign.2002,38:863-883.
[46]盆洪民.淬硬钢高速切削过程的有限元仿真.硕士学位论文.哈尔滨:哈尔滨理工大学，2007.
[47]黄先德.金属纤维切削加工的三维有限元模拟.硕士学位论文.广州:华南理工大学，2004.
[48]段春争.正交切削高强度钢绝热剪切行为的微观机理研究.博士学位论文.大连:大连理工大学，2005.
[49] B. Wang, V.P.W.Shim.Determination of inelastic heat fraction of OFHC copperthrough dynamic compression. International Journal of Impact Engineering.2010,37:50-68.
[50] Patrice Longere, Andre Dragon. Evaluation of the inelastic heat fraction in thecontext of microstructure-supported dynamic plasticity modelling. International Journal ofImpact Engineering.2008,35:992-999.
[51]曹金凤，石亦平.ABAQUS有限元分析常见问题解答.北京:机械工业出版社,2009:134-135.
[52]游煌煌，仲崇生等.机械制造技术.郑州:郑州大学出版社,2008:134-143.
[53] Christian Hortig, Bob Svendsen. Simulation of chip formation during high-speedcutting. Journal of Materials Processing Technology.2007,3:66-76.
[54]刘展.ABAQUS6.6基础教程与实例详解..北京:中国水利水电出版社,2008:1-5.
[55] Chandrakanth Shet, Xiaomin Deng. Finite element analysis of the orthogonal metalcutting process. Journal of Materials Processing Technology.2000,105:95-109.
[56] Eu-Gene Ng，David K. Aspinwall. Modelling of hard part machining. Journal ofMaterials Processing Technology.2002,127:222-229.
[57]刘力菱.高铬铸铁件热应力场数值模拟研究.硕士学位论文.成都:四川大学，2000.
[58]焦玉琴.高铬铸铁件凝固过程温度场数值模拟的研究.硕士学位论文.成都:四川大学，2000.
[59]肖诗纲.刀具材料及其合理选择.第二版.北京:机械工业出版社,1990:106-204.
[60] P.Fallbohmer, C.A. Rodriguez. High-speed machining of cast iron and alloy steelsfor die and mold manufacturing. Journal of Materials ProcessingTechnology.2000,98:104-115.
[61] Martin Baker. Finite element simulation of high-speed cutting forces. Journal ofMaterials Processing Technology.2006,176:117-126. Technology.2005,98:1204-1215.
[62] W. Grzesik, M. Bartoszuk, P. Nieslony. Finite element modelling of temperaturedistribution in the cutting zone in turning processes with differently coated tools. Journal ofMaterials Processing.
[2]郝石坚.高铬耐磨铸铁.北京:煤炭工业出版社，1993:1-1，287-293，77-78.
[3]陈璟琚，卿上胜等.合金高铬铸铁及其应用.北京:冶金工业出版社，1999:1-1，11-12.
[4]太原市金属切削刀具协会.金属切削实用刀具技术.第二版.北京:机械工业出版社，2002:216-221.
[5]齐笑冰，李卫等.GB/T，8263-1999.抗磨白口铸铁件.北京:中国标准出版社，2000.
[6]汤道华.Al2O3+TiC混合陶瓷刀具加工高铬铸铁辊的实践.江苏冶金.2002，30.3:40-41.
[7]朱正芳.高铬白口铸铁的切削试验.水利电力机械.1984、2:29-32.
[8]林学贤.氮化硅刀具加工高铬白口铁的试验.机械工艺师.1993、2:7-9.
[9]王国顺，戴锦春等.陶瓷刀具切削高铬铸铁切削用量的优化计算.新技术新工艺.2001、4:12-14.
[10]朱从容，王魄.PCBN刀具在加工高铬白口铸铁中的应用.精密制造与自动化.2008、2:60-62.
[11]俞汉清，陈金德.金属塑性成型原理.北京:机械工业出版社,2008:260-261.
[12]庄茁，由小川等.基于ABAQUS的有限元分析和应用.北京:清华大学出版社,2009:6-7.
[13]朱文明.高速切削Ti6Al4V切屑形成仿真研究.硕士学位论文.南京:南京航空航天大学，2007.
[14]邓文君，夏伟等.有限元法在切削加工过程分析中的应用.工具技术.2004,38.11:20-26.
[15] Zienkiewicz O.C.Analysis of the mechanism of orthogonal machining by the finiteelement method.Japan Soc.Prec.Eng.1971,37.7:503-508.
[16] Shirakashi T,Usui E.Simulation analysis of orthogonal metal cutting process.JapanSoc.Prec.Eng.1976,42.5:340-345.
[17] Iwata K,Osakada K,Terasaka Y.Process modeling of orthogonal cutting by therigid-plastic finite element method.Eng.Mater.Technol.1984,106:132-138.
[18] Maekawa K,Maeda M.Simulation analysis of three-dimensional continuous chipformation processes.FEM formulation and a few results.JapanSoc.Prec.Eng.1993,59.11:1827-1833.
[19] Ueda K,Manabe K amd Nozaki S.Rigid-plastic FEM of three-dimensional cuttingmechanism. simulation of plain milling process. Japan Soc.Prec.Eng.1996,62.4:526-531.
[20]刘成文.金属切削加工过程的有限元分析.硕士学位论文.杭州:浙江大学，2002.
[21]于贻鹏.金属切削过程的有限元仿真研究.硕士学位论文.大连:大连理工大学，2005.
[22]刘胜.钛合金正交切削的温度场和切削仿真与试验研究.硕士学位论文.南京:南京航空航天大学，2007.
[23]白万金.航空薄壁件精密铣削加工变形的预测理论及方法研究.博士学位论文.杭州:浙江大学，2008.
[24]房志良，杜学铭等.高铬铸铁抗泥沙磨损性能实验研究.航海工程.2007，36.5:35-37.
[25]甘宅平.高铬铸铁组织及元素分布的研究.钢铁研究.2003、4:41-42.
[26] Maratray F，Poulalion.Austenite Retention in High Cr White Iron.AFSTrans.1982:795-804.
[27]郝石坚.现代铸铁学.第二版.北京:冶金工业出版社,2009:248-255.
[28]郑中甫，孟祥东等.碳含量对高铬铸铁性能的影响.热加工工艺.2007,36.9:38-40.
[29]方亮，饶启昌等.铬系白口铸铁的磨损与断裂特性.西安交通大学学报.1987,21.6:12-18.
[30]陈德华.热处理与高铬铸铁的韧性.硕士学位论文.福州:福州大学，2002.
[31] W.L.Guesser，彭规锦等.铌在高铬铸铁中的应用.铸造.1987、2:41-42.
[32]刘少平，苏丹.钒、钛对高铬铸铁中碳化物形态及耐磨性的影响.热加工工艺.2006,35.1:30-31.
[33]谈淑咏.热处理对高铬铸铁组织和性能的影响.盐城工学院学报(自然科学版).2008,21.1:35-36，46-46，56-56.
[34]阮景奎.汽车覆盖件模具高速切削加工过程的数值模拟与关键工艺技术研究.博士学位论文.杭州:浙江大学，2007.
[35]胡昌明.镁铝合金（MB2）的动态力学性能研究.硕士学位论文.合肥:中国科学技术大学，2003.
[36]刘旭红，黄西成等.强动载荷下金属材料塑性变形本构模型评述.力学进展.2007,37.3:361-374.
[37] Johson G R ,Cook W H. A constitutive model and data for metals subjected to largestrains，high strain rates and high temperatures.Proceedings of the Seventh InternationalSymposium on Ballistics.1983:541-547.
[38] A.S. Milani, W.Dabboussi, J.A.Nemes. An improved multi-objective identificationof Johnson–Cook material parameters. International Journal of ImpactEngineering.2009,36:294-302.
[39]梁文杰.硬态切削过程的有限元仿真.硕士学位论文.哈尔滨:哈尔滨理工大学，2005.
[40]董辉跃.航空整体结构件加工过程的数值仿真.博士学位论文.杭州:浙江大学，2004.
[41] KomvoPoulos F K，Erpenbeek S A.Modeling of orthogonal metal cutting.Journal ofengineering for industry.1991，113.3:253-267
[42] Carroll J T，Strenkowski J S.Finite element models orthogonal cutting withapplication single point diamond turning.International Journal of MechanicalScience.1988,30.11:899-920.
[43] Liangchi Zhang. On the separation criteria in the simulation of orthogonal metalcutting using the finite element method.1999,89:273-278.
[44]陈志刚.金属切削过程及内圆磨削过程有限元仿真.硕士学位论文.湘潭:湘潭大学，2007.
[45] Guoqin Shi, Xiaomin Deng, Chandrakanth Shet. A finite element study of the effectof friction in orthogonal metal cutting. Finite Elements in Analysis andDesign.2002,38:863-883.
[46]盆洪民.淬硬钢高速切削过程的有限元仿真.硕士学位论文.哈尔滨:哈尔滨理工大学，2007.
[47]黄先德.金属纤维切削加工的三维有限元模拟.硕士学位论文.广州:华南理工大学，2004.
[48]段春争.正交切削高强度钢绝热剪切行为的微观机理研究.博士学位论文.大连:大连理工大学，2005.
[49] B. Wang, V.P.W.Shim.Determination of inelastic heat fraction of OFHC copperthrough dynamic compression. International Journal of Impact Engineering.2010,37:50-68.
[50] Patrice Longere, Andre Dragon. Evaluation of the inelastic heat fraction in thecontext of microstructure-supported dynamic plasticity modelling. International Journal ofImpact Engineering.2008,35:992-999.
[51]曹金凤，石亦平.ABAQUS有限元分析常见问题解答.北京:机械工业出版社,2009:134-135.
[52]游煌煌，仲崇生等.机械制造技术.郑州:郑州大学出版社,2008:134-143.
[53] Christian Hortig, Bob Svendsen. Simulation of chip formation during high-speedcutting. Journal of Materials Processing Technology.2007,3:66-76.
[54]刘展.ABAQUS6.6基础教程与实例详解..北京:中国水利水电出版社,2008:1-5.
[55] Chandrakanth Shet, Xiaomin Deng. Finite element analysis of the orthogonal metalcutting process. Journal of Materials Processing Technology.2000,105:95-109.
[56] Eu-Gene Ng，David K. Aspinwall. Modelling of hard part machining. Journal ofMaterials Processing Technology.2002,127:222-229.
[57]刘力菱.高铬铸铁件热应力场数值模拟研究.硕士学位论文.成都:四川大学，2000.
[58]焦玉琴.高铬铸铁件凝固过程温度场数值模拟的研究.硕士学位论文.成都:四川大学，2000.
[59]肖诗纲.刀具材料及其合理选择.第二版.北京:机械工业出版社,1990:106-204.
[60] P.Fallbohmer, C.A. Rodriguez. High-speed machining of cast iron and alloy steelsfor die and mold manufacturing. Journal of Materials ProcessingTechnology.2000,98:104-115.
[61] Martin Baker. Finite element simulation of high-speed cutting forces. Journal ofMaterials Processing Technology.2006,176:117-126. Technology.2005,98:1204-1215.
[62] W. Grzesik, M. Bartoszuk, P. Nieslony. Finite element modelling of temperaturedistribution in the cutting zone in turning processes with differently coated tools. Journal ofMaterials Processing.