【摘要】：H13鋼硬態(tài)切削具有大塑性變形、高應(yīng)變、高切削熱等特點(diǎn),切削區(qū)材料的晶體會(huì)發(fā)生劇烈的變形和材料相變,形成變質(zhì)層。且切屑通常呈現(xiàn)鋸齒狀,鋸齒形切屑變質(zhì)層的存在對(duì)刀具與切屑之間的摩擦產(chǎn)生影響,影響切削溫度、切削力與刀具磨損等,因此研究切屑變質(zhì)層的形成機(jī)理具有重要的意義。本文依托國(guó)家自然科學(xué)基金的資助,研究了切削過(guò)程應(yīng)力、應(yīng)變、溫度場(chǎng)等物理量的形成機(jī)理,并探究了切屑變質(zhì)層的相變機(jī)制,分析了加工表面完整性,為優(yōu)化銑削工藝,獲得性能符合要求的工件提供技術(shù)支持。主要研究工作如下:(1)建立了 H13鋼硬態(tài)銑削二維有限元仿真模型,對(duì)銑削過(guò)程進(jìn)行了仿真模擬,并對(duì)有限元模型仿真結(jié)果的有效性進(jìn)行了驗(yàn)證。模型結(jié)果表明,銑削過(guò)程(順銑)中,切屑的厚度由厚變薄,在銑削初始階段切屑成鋸齒狀,進(jìn)而隨著刀具的運(yùn)動(dòng),切屑厚度減小,切屑慢慢變成連續(xù)形態(tài)。與實(shí)驗(yàn)結(jié)果對(duì)比,仿真切削力的誤差不超過(guò)10%,驗(yàn)證了有限元模型的準(zhǔn)確性。研究分析了銑削過(guò)程中切削溫度隨切削速度與刀具鈍圓半徑的變化規(guī)律(2)基于有限元仿真的結(jié)果,分析了 H13鋼切屑形成過(guò)程及變質(zhì)層相變。研究了切屑背面與絕熱剪切帶內(nèi)的應(yīng)力、應(yīng)變、溫度分布與實(shí)驗(yàn)變質(zhì)層分布規(guī)律。結(jié)果表明,切屑背面與絕熱剪切帶內(nèi)變質(zhì)層分布與應(yīng)力、應(yīng)變、溫度高度吻合。絕熱剪切帶內(nèi)變質(zhì)層與晶粒變形、再結(jié)晶有關(guān),切屑背面變質(zhì)層的形成與相變有關(guān)。通過(guò)理論分析研究了硬態(tài)銑削過(guò)程中合金元素、應(yīng)力、應(yīng)變能對(duì)奧氏體化相變溫度的影響規(guī)律。結(jié)合有限元仿真結(jié)果,對(duì)硬態(tài)銑削變質(zhì)層尺寸進(jìn)行了預(yù)測(cè),預(yù)測(cè)結(jié)果與實(shí)驗(yàn)結(jié)果誤差不超過(guò)15%,對(duì)變質(zhì)層的相變機(jī)制研究有著重要的意義。(3)結(jié)合不同切削參數(shù),研究了考慮刀具鈍圓半徑影響的H13鋼硬態(tài)銑削表面完整性各評(píng)價(jià)指標(biāo)變化規(guī)律。對(duì)加工表面形貌進(jìn)行了分析,銑削表面形貌具有明顯的周期性。分析了不同參數(shù)對(duì)表面粗糙度的影響規(guī)律,建立了考慮刀具鈍圓半徑影響的表面粗糙度的經(jīng)驗(yàn)?zāi)Ｐ筒⑦M(jìn)行了顯著性檢驗(yàn)。分析了不同參數(shù)對(duì)殘余應(yīng)力的影響規(guī)律,并建立了基于二次多項(xiàng)式的殘余應(yīng)力經(jīng)驗(yàn)?zāi)Ｐ�。以加工硬化作為評(píng)價(jià)指標(biāo)分析不同參數(shù)條件下的工件表面質(zhì)量,研究了表層顯微硬度、表面層硬化程度隨參數(shù)的變化規(guī)律。研究發(fā)現(xiàn),加工硬化程度隨鈍圓半徑的增大而顯著增大。對(duì)工件亞表層的顯微硬度分析發(fā)現(xiàn),顯微維氏硬度隨層深的增大而逐漸減小,即隨著層深的增大,塑性強(qiáng)化作用逐漸減小,熱軟化作用逐漸加強(qiáng),在一定深度內(nèi)熱軟化作用大于強(qiáng)化作用,硬度小于基體硬度。本研究分析了切屑變質(zhì)層的形成機(jī)制,研究了 H13鋼銑削加工表面完整性,可以為揭示H]3鋼銑削機(jī)理、指導(dǎo)銑削加工工藝并獲得良好的加工表面完整性提供技術(shù)支持。
[Abstract]:The hard cutting of H13 steel is characterized by large plastic deformation, high strain and high cutting heat. The crystal in the cutting zone will undergo severe deformation and material transformation, forming a metamorphic layer. The chip is usually serrated, and the existence of sawtooth chip metamorphic layer affects the friction between cutting tool and chip, affects cutting temperature, cutting force and tool wear, etc. Therefore, it is of great significance to study the formation mechanism of chip metamorphic layer. In this paper, the formation mechanism of stress, strain and temperature field in cutting process is studied with the aid of the National Natural Science Foundation. The mechanism of phase transition of chip metamorphic layer is discussed, and the machining surface integrity is analyzed in order to optimize milling process. Provide technical support for obtaining performance-compliant artifacts. The main research work is as follows: (1) the two-dimensional finite element simulation model for hard milling of H13 steel is established. The milling process is simulated and the validity of the simulation results of the finite element model is verified. The model results show that the chip thickness changes from thick to thin in the milling process, and the chip becomes sawtooth in the initial stage of milling. Then, with the movement of the cutter, the chip thickness decreases and the chip becomes a continuous shape. Compared with the experimental results, the error of the simulation cutting force is less than 10, which verifies the accuracy of the finite element model. The variation of cutting temperature with cutting speed and cutting tool radius during milling is studied. (2) based on the results of finite element simulation, the formation process of H13 steel chip and the phase transformation of the modified layer are analyzed. The stress, strain, temperature distribution and experimental metamorphic layer distribution in the chip backside and adiabatic shear band are studied. The results show that the distribution of metamorphic layer on the back side of chip and adiabatic shear zone is highly consistent with stress strain and temperature. The metamorphic layer in adiabatic shear zone is related to grain deformation and recrystallization, and the formation of metamorphic layer on the back of chip is related to phase transformation. The influence of alloying elements, stress and strain energy on austenitic transformation temperature during hard milling was studied theoretically. Combined with the finite element simulation results, the size of the hard milling metamorphic layer is predicted. The error between the prediction result and the experimental result is not more than 15. It is of great significance to study the phase transition mechanism of the metamorphic layer. (3) combined with different cutting parameters, The changes of evaluation indexes of surface integrity of H13 steel hard milling considering the influence of blunt radius of cutting tools are studied. The machined surface morphology is analyzed, and the milling surface morphology has obvious periodicity. The influence of different parameters on surface roughness is analyzed. The empirical model of surface roughness considering the influence of blunt radius of cutting tool is established and the significance test is carried out. The influence of different parameters on residual stress is analyzed, and an empirical model of residual stress based on quadratic polynomial is established. The surface quality of workpiece under different parameters was analyzed by using work hardening as evaluation index. The variation of surface microhardness and hardening degree of surface layer with parameters was studied. It is found that the degree of work hardening increases with the increase of the radius of blunt circle. The microhardness analysis of the subsurface layer of the workpiece shows that the microhardness decreases with the increase of the layer depth, that is, with the increase of the layer depth, the plastic strengthening effect decreases gradually, and the thermal softening effect is gradually strengthened. The effect of thermal softening is greater than that of strengthening in a certain depth, and the hardness is smaller than that of matrix. In this paper, the formation mechanism of chip metamorphic layer is analyzed, and the surface integrity of H13 steel milling is studied, which can provide technical support for revealing milling mechanism of H] 3 steel, guiding milling process and obtaining good surface integrity.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類(lèi)號(hào)】：TG54

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