高溫合金GH4169的切削加工性評(píng)價(jià)方法和本構(gòu)模型研究
發(fā)布時(shí)間：2018-08-23 07:51
【摘要】：高溫合金GH4169是典型的難加工材料,改善其切削加工性、提高表面加工質(zhì)量是降低其應(yīng)用成本,提高工件服役能力的重要途徑。本文研究了面銑加工GH4169時(shí)的刀具壽命和刀具失效機(jī)理,提出了新的切削加工性評(píng)價(jià)方法；研究了面銑加工GH4169時(shí)的切削參數(shù)對(duì)加工表面完整性和工件表面三點(diǎn)彎曲疲勞壽命的影響；建立了考慮熱力耦合作用的GH4169材料本構(gòu)模型,進(jìn)行了有限元切削仿真研究；研究了干切削、濕切削和低溫切削GH4169時(shí)的刀具壽命、刀具失效機(jī)理和加工表面完整性。研究了在較大切削速度范圍內(nèi)銑削高溫合金時(shí)的刀具壽命和刀具失效機(jī)理,提出了切削加工性評(píng)價(jià)新方法。在高溫合金GH4169的銑削加工中,刀具壽命隨切削速度的增加而急劇降低。當(dāng)切削速度較低時(shí),刀具失效形式是后刀面磨損,磨損機(jī)理為典型的磨粒磨損。隨著切削速度的增加,刀具失效形式轉(zhuǎn)變?yōu)榈都馄茡p。在中等切削速度下,刀具在機(jī)械沖擊和熱沖擊共同作用下產(chǎn)生裂紋、導(dǎo)致崩刃。在較高切削速度時(shí),熱沖擊是刀具產(chǎn)生裂紋、導(dǎo)致崩刃的主要原因。提出了采用刀具壽命對(duì)切削速度的敏感系數(shù)和刀具失效形式由磨損轉(zhuǎn)變?yōu)槠茡p的臨界切削速度兩個(gè)指標(biāo)評(píng)價(jià)工件材料切削加工性的新方法。刀具壽命對(duì)切削速度敏感系數(shù)越大,表明該材料的切削加工性越差；刀具失效形式由磨損轉(zhuǎn)變?yōu)槠茡p的臨界切削速度越低,表明該材料的切削加工性越差。采用此方法評(píng)價(jià)了四種高溫合金的切削加工性,其切削加工性由難至易排序?yàn)镚H605 GH4169 GH4033 GH2132。研究了面銑加工GH4169時(shí)的切削參數(shù)對(duì)加工表面完整性和工件表面三點(diǎn)彎曲疲勞壽命的影響。在所選切削參數(shù)范圍內(nèi),切削速度對(duì)表面粗糙度影響較小,隨著切削速度的增加,表面粗糙度先減小后增大；隨著每齒進(jìn)給量的增加,表面粗糙度增大。工件表面加工硬化層厚度小于20gm,隨著切削速度和每齒進(jìn)給量的增加,工件表面硬度略有增加。加工表面存在殘余拉應(yīng)力,切削速度對(duì)殘余應(yīng)力的影響規(guī)律不明顯,殘余拉應(yīng)力隨著每齒進(jìn)給量的增加而增大。在三點(diǎn)彎曲疲勞壽命實(shí)驗(yàn)中,試樣發(fā)生了多源疲勞斷裂,疲勞裂紋萌生于加工表面。在所選切削參數(shù)范圍內(nèi),切削速度對(duì)工件表面疲勞壽命的影響較小。每齒進(jìn)給量對(duì)工件表面疲勞壽命的影響較顯著,隨著每齒進(jìn)給量的增加,工件表面粗糙度增大,因此表面應(yīng)力集中系數(shù)增大,導(dǎo)致工件表面疲勞壽命降低；加工硬化無明顯變化,對(duì)加工表面疲勞壽命的影響可以忽略；殘余拉應(yīng)力增大,工件表面疲勞壽命降低,但殘余拉應(yīng)力在疲勞過程中發(fā)生了松弛,降低了殘余應(yīng)力對(duì)疲勞壽命的影響程度。建立了考慮熱力耦合作用的GH4169材料本構(gòu)模型,并進(jìn)行了有限元切削仿真研究。通過霍普金森壓桿實(shí)驗(yàn),在500-800℃溫度范圍和5000～11000s-1應(yīng)變率范圍內(nèi)研究了GH4169的動(dòng)態(tài)力學(xué)性能。結(jié)果表明,材料動(dòng)態(tài)變形中存在應(yīng)變率強(qiáng)化效應(yīng)和應(yīng)變率軟化效應(yīng)。在不同溫度下,應(yīng)變率強(qiáng)化效應(yīng)和應(yīng)變率軟化效應(yīng)的臨界溫度不同,應(yīng)變率對(duì)力學(xué)性能影響的規(guī)律性不強(qiáng)。不同應(yīng)變率對(duì)應(yīng)的溫度熱軟化作用規(guī)律保持不變。建立了高溫高應(yīng)變率下的GH4169材料本構(gòu)模型,通過切削仿真和實(shí)驗(yàn)驗(yàn)證,證明了該本構(gòu)模型的適用性,其仿真精度高于現(xiàn)有模型。采用本文建立的材料本構(gòu)模型進(jìn)行了正交車削GH4169仿真,研究了刀具刃口半徑對(duì)切削力、切削變形區(qū)溫度場(chǎng)和應(yīng)變率場(chǎng)的影響。隨著刀具刃口半徑的增大,刀具對(duì)工件材料的剪切去除作用降低,犁耕作用增強(qiáng),切削力增大；第一變形區(qū)和第三變形區(qū)在刀具刃口附近擴(kuò)展,導(dǎo)致溫度場(chǎng)中高溫區(qū)域擴(kuò)大。研究了干切削、濕切削和低溫切削GH4169時(shí)的刀具壽命、刀具失效機(jī)理和加工表面完整性。在端面車削GH4169中,與干切削相比,濕切削和低溫切削能顯著提高刀具壽命。干切削和濕切削時(shí)刀具失效機(jī)理為磨粒磨損和粘結(jié)磨損,低溫切削時(shí),切屑流向的改變和切屑上毛刺的產(chǎn)生是導(dǎo)致邊界磨損的主要原因。在面銑削GH4169中,與干切削相比,濕切削和低溫切削能顯著提高刀具壽命,濕切削和低溫切削抑制了擴(kuò)散磨損和氧化磨損,但在低溫切削時(shí),較大的熱沖擊仍導(dǎo)致熱裂紋。在端面車削GH4169中,與干切削相比,在較低的切削速度下,濕切削和低溫切削得到的加工表面粗糙度較大；在較高的切削速度下,濕切削和低溫切削得到的加工表面粗糙度較小。在于切削、濕切削和低溫切削條件下,工件表面都出現(xiàn)了加工軟化現(xiàn)象,低溫切削得到的工件表面軟化程度低；隨著切削速度的增加,工件表面軟化程度增強(qiáng)。隨著切削速度的增加,干切削的加工表面殘余拉應(yīng)力增大；濕切削的加工表面殘余壓應(yīng)力轉(zhuǎn)變?yōu)闅堄嗬瓚?yīng)力；低溫切削的加工表面在較高速度下仍保持殘余壓應(yīng)力。
[Abstract]:Superalloy GH4169 is a typical hard-to-machine material. Improving its machinability and surface quality is an important way to reduce its application cost and improve the service ability of workpiece. The influence of cutting parameters on machining surface integrity and three-point bending fatigue life of workpiece surface at GH4169 is studied; the constitutive model of GH4169 considering thermo-mechanical coupling is established, and the finite element cutting simulation is carried out; the tool life, tool failure mechanism and machining table of GH4169 under dry cutting, wet cutting and low temperature cutting are studied. In the milling of superalloy GH4169, the tool life decreases sharply with the increase of cutting speed. When the cutting speed is low, the tool failure mode is the rear tool face. The wear mechanism is typical abrasive wear. With the increase of cutting speed, the failure mode of the tool changes into tool tip breakage. At moderate cutting speed, the tool cracks under the combined action of mechanical impact and thermal shock, resulting in edge collapse. A new method for evaluating the machinability of workpiece materials by using the sensitivity coefficient of tool life to cutting speed and the critical cutting speed from wear to breakage is proposed. In order to reduce the critical cutting speed, the worse the machinability of the material is indicated. The machinability of four superalloys is evaluated by this method. The machinability of the superalloys is in the order of GH605 GH4169 GH4033 GH2132. The surface roughness decreases first and then increases with the increase of cutting speed. The surface roughness increases with the increase of feed per tooth. The thickness of hardened layer is less than 20gm, and with the increase of cutting speed and feed per tooth. In the three-point bending fatigue life test, multi-source fatigue fracture occurred and fatigue cracks initiated on the machined surface. Within the range of parameters, cutting speed has little effect on the surface fatigue life of the workpiece. The influence of feed per tooth on the surface fatigue life of the workpiece is more significant. With the increase of feed per tooth, the surface roughness of the workpiece increases, so the surface stress concentration coefficient increases, which results in the decrease of the surface fatigue life of the workpiece. The influence of the residual tensile stress on the fatigue life of the machined surface can be neglected; the fatigue life of the workpiece surface decreases with the increase of the residual tensile stress, but the residual tensile stress relaxes during the fatigue process, which reduces the influence of the residual stress on the fatigue life. The dynamic mechanical properties of GH4169 were studied by Hopkinson compression bar test in the temperature range of 500-800 C and strain rate range of 5000-11000s-1. The results show that strain rate hardening effect and strain rate softening effect exist in the dynamic deformation of GH4169. At different temperatures, strain rate hardening effect and critical temperature of strain rate softening effect are studied. The constitutive model of GH4169 at high temperature and high strain rate is established. The applicability of the constitutive model is proved by cutting simulation and experimental verification. The simulation accuracy is higher than the existing model. The material constitutive model is established and simulated by orthogonal turning GH4169. The effects of tool edge radius on cutting force, temperature field and strain rate field in cutting deformation zone are studied. The tool life, tool failure mechanism and surface integrity in dry cutting, wet cutting and low temperature cutting GH4169 were studied. In end face turning GH4169, wet cutting and low temperature cutting can significantly increase tool life compared with dry cutting. In face milling GH4169, wet cutting and low temperature cutting can significantly increase tool life compared with dry cutting, while wet cutting and low temperature cutting inhibit diffusion wear and oxygen. In GH4169, compared with dry cutting, the surface roughness of wet cutting and low-temperature cutting is higher at lower cutting speed, and that of wet cutting and low-temperature cutting is lower at higher cutting speed. Under cutting, wet cutting and low-temperature cutting conditions, the workpiece surface softening phenomenon appears, and the workpiece surface softening degree is low after low-temperature cutting; with the increase of cutting speed, the workpiece surface softening degree increases. With the increase of cutting speed, the residual tensile stress on the dry cutting surface increases; and the surface residual in wet cutting. The residual compressive stress is transformed into residual tensile stress, and the surface machined at low temperature remains residual compressive stress at higher speed.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG506
本文編號(hào)：2198364
[Abstract]:Superalloy GH4169 is a typical hard-to-machine material. Improving its machinability and surface quality is an important way to reduce its application cost and improve the service ability of workpiece. The influence of cutting parameters on machining surface integrity and three-point bending fatigue life of workpiece surface at GH4169 is studied; the constitutive model of GH4169 considering thermo-mechanical coupling is established, and the finite element cutting simulation is carried out; the tool life, tool failure mechanism and machining table of GH4169 under dry cutting, wet cutting and low temperature cutting are studied. In the milling of superalloy GH4169, the tool life decreases sharply with the increase of cutting speed. When the cutting speed is low, the tool failure mode is the rear tool face. The wear mechanism is typical abrasive wear. With the increase of cutting speed, the failure mode of the tool changes into tool tip breakage. At moderate cutting speed, the tool cracks under the combined action of mechanical impact and thermal shock, resulting in edge collapse. A new method for evaluating the machinability of workpiece materials by using the sensitivity coefficient of tool life to cutting speed and the critical cutting speed from wear to breakage is proposed. In order to reduce the critical cutting speed, the worse the machinability of the material is indicated. The machinability of four superalloys is evaluated by this method. The machinability of the superalloys is in the order of GH605 GH4169 GH4033 GH2132. The surface roughness decreases first and then increases with the increase of cutting speed. The surface roughness increases with the increase of feed per tooth. The thickness of hardened layer is less than 20gm, and with the increase of cutting speed and feed per tooth. In the three-point bending fatigue life test, multi-source fatigue fracture occurred and fatigue cracks initiated on the machined surface. Within the range of parameters, cutting speed has little effect on the surface fatigue life of the workpiece. The influence of feed per tooth on the surface fatigue life of the workpiece is more significant. With the increase of feed per tooth, the surface roughness of the workpiece increases, so the surface stress concentration coefficient increases, which results in the decrease of the surface fatigue life of the workpiece. The influence of the residual tensile stress on the fatigue life of the machined surface can be neglected; the fatigue life of the workpiece surface decreases with the increase of the residual tensile stress, but the residual tensile stress relaxes during the fatigue process, which reduces the influence of the residual stress on the fatigue life. The dynamic mechanical properties of GH4169 were studied by Hopkinson compression bar test in the temperature range of 500-800 C and strain rate range of 5000-11000s-1. The results show that strain rate hardening effect and strain rate softening effect exist in the dynamic deformation of GH4169. At different temperatures, strain rate hardening effect and critical temperature of strain rate softening effect are studied. The constitutive model of GH4169 at high temperature and high strain rate is established. The applicability of the constitutive model is proved by cutting simulation and experimental verification. The simulation accuracy is higher than the existing model. The material constitutive model is established and simulated by orthogonal turning GH4169. The effects of tool edge radius on cutting force, temperature field and strain rate field in cutting deformation zone are studied. The tool life, tool failure mechanism and surface integrity in dry cutting, wet cutting and low temperature cutting GH4169 were studied. In end face turning GH4169, wet cutting and low temperature cutting can significantly increase tool life compared with dry cutting. In face milling GH4169, wet cutting and low temperature cutting can significantly increase tool life compared with dry cutting, while wet cutting and low temperature cutting inhibit diffusion wear and oxygen. In GH4169, compared with dry cutting, the surface roughness of wet cutting and low-temperature cutting is higher at lower cutting speed, and that of wet cutting and low-temperature cutting is lower at higher cutting speed. Under cutting, wet cutting and low-temperature cutting conditions, the workpiece surface softening phenomenon appears, and the workpiece surface softening degree is low after low-temperature cutting; with the increase of cutting speed, the workpiece surface softening degree increases. With the increase of cutting speed, the residual tensile stress on the dry cutting surface increases; and the surface residual in wet cutting. The residual compressive stress is transformed into residual tensile stress, and the surface machined at low temperature remains residual compressive stress at higher speed.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG506
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