模具鋼硬態(tài)切削過(guò)程刀具磨損及表面淬火效應(yīng)研究_圖文

1、工學(xué)博士學(xué)位論文模具鋼硬態(tài)切削過(guò)程刀具磨損及表面淬火效應(yīng)研究岳彩旭哈爾濱理工大學(xué)2012年12月國(guó)內(nèi)圖書分類號(hào)：TG501工學(xué)博士學(xué)位論文模具鋼硬態(tài)切削過(guò)程刀具磨損及表面淬火效應(yīng)研究博 士 研究生：岳彩旭導(dǎo) 師：劉獻(xiàn)禮申請(qǐng)學(xué)位級(jí)別：工學(xué)博士學(xué) 科、專 業(yè)：機(jī)械制造及其自動(dòng)化所 在 單 位：機(jī)械動(dòng)力工程學(xué)院答 辯 日 期：2012年12月授予學(xué)位單位：哈爾濱理工大學(xué)Classified Index: TG501Dissertation for the Doctoral Degree in EngineeringTool Wear and Surface Quenching Mechanism F

2、orHard Cutting Process of Die SteelCandidate:Yue Caixu Supervisor: Liu XianliAcademic Degree Applied for:Doctor of EngineeringSpecialty:Mechanical Manufacture and Automation Date of Oral Examination:Dec,2012 University: Harbin University of Science andTechnology哈爾濱理工大學(xué)博士學(xué)位論文原創(chuàng)性聲明本人鄭重聲明：此處所提交的博士學(xué)位論文模

3、具鋼硬態(tài)切削過(guò)程刀具磨損及表面淬火效應(yīng)研究，是本人在導(dǎo)師指導(dǎo)下，在哈爾濱理工大學(xué)攻讀博士學(xué)位期間獨(dú)立進(jìn)行研究工作所取得的成果。據(jù)本人所知，論文中除已注明部分外不包含他人已發(fā)表或撰寫過(guò)的研究成果。對(duì)本文研究工作做出貢獻(xiàn)的個(gè)人和集體，均已在文中以明確方式注明。本聲明的法律結(jié)果將完由本人承擔(dān)。作者簽名：岳彩旭 日期：2012年 12 月 7日哈爾濱理工大學(xué)博士學(xué)位論文使用授權(quán)書模具鋼硬態(tài)切削過(guò)程刀具磨損及表面淬火效應(yīng)研究系本人在哈爾濱理工大學(xué)攻讀博士學(xué)位期間在導(dǎo)師指導(dǎo)下完成的博士學(xué)位論文。本論文的研究成果歸哈爾濱理工大學(xué)所有，本論文的研究?jī)?nèi)容不得以其它單位的名義發(fā)表。本人完全了解哈爾濱理工大學(xué)關(guān)于保

4、存、使用學(xué)位論文的規(guī)定，同意學(xué)校保留并向有關(guān)部門提交論文和電子版本，允許論文被查閱和借閱。本人授權(quán)哈爾濱理工大學(xué)可以采用影印、縮印或其他復(fù)制手段保存論文，可以公布論文的全部或部分內(nèi)容。本學(xué)位論文屬于在 年解密后適用授權(quán)書。 不保密 。（請(qǐng)?jiān)谝陨舷鄳?yīng)方框內(nèi)打）作者簽名：岳彩旭 日期：2012 年 12月7 日導(dǎo)師簽名：劉獻(xiàn)禮 日期：2012年 12月 7 日摘 要- I - 摘 要摘 要硬態(tài)切削工藝由于具有良好的加工環(huán)保性和加工柔性，該工藝已逐步取代磨削工藝成為模具鋼的精加工工藝，它是具有廣泛應(yīng)用前景的先進(jìn)加工技術(shù)。但硬態(tài)切削加工工藝中諸如刀具磨損、切削過(guò)程熱流特性和已加工表面完整性等方面的理論

5、與技術(shù)還存在諸多沒(méi)有徹底揭示之處。所以應(yīng)該在上述方面展開(kāi)深入研究，以便促進(jìn)此新興工藝在實(shí)際加工中的應(yīng)用。為了建立切削過(guò)程的精確仿真模型，本研究系統(tǒng)闡述了切削仿真技術(shù)的關(guān)鍵技術(shù)，并采用仿真手段利用Abaqus 軟件研究了工件材料本構(gòu)關(guān)系，針對(duì)典型高強(qiáng)度鋼Cr12MoV 的霍普金森實(shí)驗(yàn)得到了工件材料Joshon-Cook 模型參數(shù)的敏感性關(guān)系；聯(lián)合綜合優(yōu)化軟件Isight ，通過(guò)Abaqus 仿真軟件的二次開(kāi)發(fā)實(shí)現(xiàn)了切削力的仿真控制，為選擇合適的切削條件提供理論工具。為實(shí)現(xiàn)模具鋼硬態(tài)切削過(guò)程中刀具磨損的機(jī)理研究，本文揭示了PCBN 刀具切削模具鋼Cr12MoV 過(guò)程的刀具磨損規(guī)律，研究了刀具磨損量

6、對(duì)切屑生成機(jī)制、切削力、切削應(yīng)力和切削溫度的變化規(guī)律；采用功率譜均方根的方法研究了不同切削條件下系統(tǒng)穩(wěn)定性判據(jù)的變化規(guī)律，并通過(guò)數(shù)值建模的方法得到了刀具磨損對(duì)切削系統(tǒng)穩(wěn)定閾極限的影響，結(jié)果顯示在選定切削條件下刀具磨損加劇會(huì)導(dǎo)致切削穩(wěn)定閾極限變寬。為揭示硬態(tài)切削過(guò)程已加工表面淬火效應(yīng)，本文研究了不同升溫速率下工件材料相變點(diǎn)在切削狀態(tài)下相變圖譜位移情況；結(jié)合數(shù)值方法得到了不同刀具磨損情況下工件溫度場(chǎng)分布情況，對(duì)已加工表面的變質(zhì)層厚度進(jìn)行了預(yù)測(cè)，并利用實(shí)驗(yàn)手段得到了已加工表面變質(zhì)層受刀具磨損和切削速度的影響規(guī)律，同時(shí)也分析了淬火效應(yīng)對(duì)已加工表面硬度的影響。為揭示條件對(duì)已加工表面完整性的影響機(jī)制，本文

7、研究了硬態(tài)切削工藝切削條件對(duì)表面粗糙度的影響，建立了考慮最小切削厚度表面粗糙度仿真模型，并采用實(shí)驗(yàn)手段驗(yàn)證了模型精度；分析了刀具磨損對(duì)加工表面形貌的影響；研究了切削條件、刀具圓弧半徑和刀具磨損對(duì)殘余應(yīng)力分布的影響機(jī)制。本文以PCBN 刀具硬態(tài)切削模具鋼Cr12MoV 工藝為研究對(duì)象，通過(guò)理論分析、數(shù)值模擬和切削試驗(yàn)相結(jié)合的方法，在刀具磨損、已加工表面淬火 模具鋼硬態(tài)切削過(guò)程 刀具磨損及表面淬火效應(yīng)研究 哈爾濱理工大學(xué)工學(xué)博士學(xué)位論文- II -效應(yīng)和表面完整性等方面研究了硬態(tài)切削機(jī)理，研究結(jié)果可為模具鋼硬態(tài)切削加工技術(shù)推廣提供理論依據(jù)和技術(shù)支撐。關(guān)鍵詞 模具鋼Cr

8、12MoV ；硬態(tài)切削；PCBN 刀具；切削過(guò)程仿真；切削過(guò)程穩(wěn)定性；表面完整性Abstract- III - AbstractAbstractHard cutting processing technology has gradually become a high strength steel finishing process and has replaced the grinding process in certain occasions as well, for its good processing environmental protection, flexible and p

9、recision. Thus, this technology is an advanced processing technology with wide application prospects. But many special cutting law of the hard cutting processing technology still need to explore, especially cutting tool wear in cutting, surface quenching effect, processing surface integrity and othe

10、r aspects of the theory and technology need a systemic research, which could further promote the advanced technology.In order to establish the precise cutting process simulation model, this study introduced the key technology of the cutting simulation technology and researched the workpiece material

11、 constitutive relation using Abaqus software with the simulation method, in view of the typical high strength steel Cr12MoV of the Hopkinson experiment get the parameter sensitivity relationship of material Joshon-Cook model. Through the secondary development of Abaqus simulation software and combin

12、ing multidisciplinary system optimization Isight software to realize the control of cutting force, which provide theoretical tools the choice of appropriate cutting conditions.The system studied the tool wear mechanism of the process that PCBN tools cut die steel Cr12MoV, and analyzed the change rul

13、es of the tool wear amount to chip generation, cutting force, cutting stress and cutting temperature; The system used the way of root mean square to study the change rules of the system stability in different cutting rate and tool wear quantity, and through the numerical modeling ways to get the inf

14、luence of the tool wear to cutting system stability, and realized the prediction of the stability domain limit with the simulation method.In order to reveal the die steel Cr12MoV already processing surface quenching effect mechanism, this paper studied the workpiece material phase transitionTool Wea

15、r and Surface Quenching Mechanism For Hard Cutting Process of Die Steel哈爾濱理工大學(xué)工學(xué)博士學(xué)位論文- IV -point in different heating rate and the phase diagram of displacement in different cutting state; Combining with numerical method to get the workpiece temperature field distribution in the different tool wear

16、 condition, and predicting the thickness of already processing surface metamorphic layer, beside, by using experimental method to get the influence mechanism of the tool wear and cutting speed to finished surface metamorphic layer. At the same time, the paper also evaluated how quenching effect infl

17、uence the processing surface hardness.This paper has studied the effect of cutting conditions on surface roughness in the hard cutting processing, and established the minimum cutting thickness surface roughness simulation model, and verified the accuracy of model means combining with the experiment;

18、 it also has analyzed the effect of tool wear on machining surface morphology and the side flow generation mechanism under different cutting conditions, done a systematic research on influence of cutting condition, tool nose radius and tool wear on residual stress distribution.In this study PCBN too

19、l hard cutting die steel Cr12MoV process as the research object, through the combination of theoretical analysis, numerical simulation and cutting test, study hard state cutting mechanism in the tool wear，processed surface quenching effect surface integrity and other aspects, the results could provi

20、de the theory basis and the technical support for application of hard cutting processing technology.Keywords Mould steel Cr12MoV; Hard cutting; FEM of cutting process; PCBN tool; Cutting stability; Surface integrity目錄- V -目 錄摘 要. . I  Abstract . I II第1章 緒論 . 1 1.1 研究的目的和意義 . . 1 1.2 高

21、強(qiáng)度鋼硬態(tài)切削的特征及優(yōu)勢(shì) . 2 1.3 硬態(tài)切削技術(shù)國(guó)內(nèi)外研究現(xiàn)狀 . 3 1.3.1 切削力和切削溫度的研究 . 3 1.3.2 工件材料本構(gòu)關(guān)系的研究 . 4 1.3.3 切削過(guò)程仿真技術(shù)的研究 . 5 1.3.4 硬態(tài)切削過(guò)程刀具磨損的研究 . 7 1.3.5 硬態(tài)切削過(guò)程穩(wěn)定性的研究 . 8 1.3.6 硬態(tài)切削表面完整性的研究 . 8 1.4 課題的提出和研究?jī)?nèi)容 . 13 第2章 硬態(tài)切削過(guò)程切削力控制的仿真研究 . 15 2.1 切削過(guò)程仿真關(guān)鍵技術(shù) . 15 2.1

22、.1 刀具與切屑接觸應(yīng)力處理技術(shù) . 16 2.1.2 切屑與工件的分離準(zhǔn)則 . 16 2.2 工件材料本構(gòu)方程的研究 . 17 2.2.1 霍普金森實(shí)驗(yàn)的原理及建模 . 17 2.2.2 霍普金森實(shí)驗(yàn)的仿真結(jié)果 . 20 2.3 基于聯(lián)合仿真的切削過(guò)程控制 . 22 2.3.1 聯(lián)合仿真的設(shè)計(jì)流程 . 23 2.3.2 軟件Abaqus 與腳本軟件的過(guò)程集成 . 24 2.3.3 優(yōu)化過(guò)程參數(shù)的設(shè)定 . 24 2.3.4 仿真結(jié)果的輸出 . . 25 2.3.5 仿真結(jié)果精度的驗(yàn)證 . 26&

23、#160;2.4 本章小結(jié) . 27 第3章 模具鋼硬態(tài)切削過(guò)程PCBN 刀具磨損研究 . 28 3.1 試驗(yàn)條件設(shè)置. . 28 哈爾濱理工大學(xué)工學(xué)博士學(xué)位論文- VI - 3.2 PCBN刀具磨損機(jī)理研究. . 28 3.3 切削條件對(duì)刀具磨損影響的研究 . 31 3.3.1 切削參數(shù)對(duì)刀具磨損的影響 . 31 3.3.2 刀尖圓弧半徑對(duì)刀具磨損的影響 . 33 3.3.3 涂層對(duì)刀具磨損的影響 . 33 3.4 刀具磨損對(duì)切削過(guò)程的影響 . 35 3.4.1 刀具磨損對(duì)切屑生成機(jī)制的影響 . 35&

24、#160;3.4.2 刀具磨損對(duì)切削力的影響 . 36 3.4.3 刀具磨損對(duì)切削應(yīng)力和溫度場(chǎng)的影響. . 38 3.5 本章小結(jié) . 40 第4章 刀具磨損狀態(tài)對(duì)切削過(guò)程穩(wěn)定性的影響 . 41 4.1 切削系統(tǒng)模態(tài)參數(shù)的測(cè)定 . 41 4.2 刀具磨損對(duì)切削穩(wěn)定性的實(shí)驗(yàn)研究 . 43 4.3 基于譜密度均方根的系統(tǒng)穩(wěn)定性研究 . 44 4.3.1 系統(tǒng)穩(wěn)定性均方根的理論研究 . 44 4.3.2 穩(wěn)定性模型的實(shí)驗(yàn)驗(yàn)證 . 46 4.4 考慮刀具磨損的系統(tǒng)穩(wěn)定域研究 . 48 4.4.1 顫振的

25、線性模型 . . 48 4.4.2 磨損刀具對(duì)系統(tǒng)穩(wěn)定性極限的研究. 51 4.4.3 穩(wěn)定域極限的預(yù)測(cè) . 56 4.5 本章小結(jié) . 57 第5章 切削淬硬模具鋼表面淬火效應(yīng)的研究 . 59 5.1 模具鋼已加工表面變質(zhì)層的特性分析 . 59 5.1.1 變質(zhì)層生成機(jī)理研究 . 60 5.1.2 變質(zhì)層的元素分析 . 61 5.1.3 變質(zhì)層體積的變化 . 62 5.1.4 變質(zhì)層的晶粒細(xì)化 . 63 5.2 工件材料溫度變化歷程的研究 . 63 5.3 變質(zhì)層產(chǎn)生的臨界條件判定

26、. 64 5.3.1 變質(zhì)層產(chǎn)生臨界條件的判定 . 64 5.3.2 急劇溫升條件下Cr12MoV 相變點(diǎn)變化的研究. . 64 5.4 硬態(tài)切削過(guò)程溫度場(chǎng)分布研究 . 66 5.5 已加工表面變質(zhì)層的生成機(jī)制 . 68 目錄- VII -5.5.1 切削速度對(duì)變質(zhì)層生成的影響 . 68 5.5.2 后刀面磨損對(duì)表面變質(zhì)層產(chǎn)生的影響. . 70 5.6 模具鋼已加工表面淬硬機(jī)制的研究 . 71 5.6.1 加工硬化的評(píng)價(jià)方法 . 71 5.6.2 高強(qiáng)度鋼加工硬化試驗(yàn) . 72 5.7 本章小結(jié)

27、 . 72 第6章 切削淬硬模具鋼已加工表面完整性研究 . 73 6.1 表面完整性的定義 . . 73 6.2 已加工表面粗糙度的研究 . 74 6.2.1 切削條件對(duì)表面粗糙度的影響 . 75 6.2.2 考慮最小切削厚度表面粗糙度模型的建立 . . 76 6.2.3 表面粗糙度與刀具磨損關(guān)系的研究. . 78 6.3 高強(qiáng)度鋼已加工表面形貌的研究 . 79 6.4 已加工表面殘余應(yīng)力的研究 . 80 6.4.1 殘余應(yīng)力影響規(guī)律的分析 . 80 6.4.2 切削速度對(duì)表面殘余應(yīng)力的影響 .

28、 81 6.4.3 刀尖圓弧半徑對(duì)殘余應(yīng)力的影響 . 81 6.4.4 刀具磨損對(duì)殘余應(yīng)力分布的影響 . 82 6.4.5 材料相變引起的殘余應(yīng)力 . 83 6.5 本章小結(jié) . 83 結(jié)論. . 85 參考文獻(xiàn) . . 86 攻讀博士學(xué)位期間發(fā)表的學(xué)術(shù)論文 . . 96 致謝. . 97 哈爾濱理工大學(xué)工學(xué)博士學(xué)位論文- VIII -ContentsAbstract(In Chinese. Abstract(In English . I IIChapter 1 Introduction . . 11.1

29、 The purpose and significance of the study . 11.2 Features and advantages of hard machining of high-strength steel . . 21.3 Hard cutting technology research status at home and abroad . . 31.3.1 Study of cutting forces and temperature . . 31.3.2 Study on the constitutive relationship of workpiece mat

30、erial. . 41.3.3 Cuting process simulation technolgy research . 51.3.4 Hard cutting process research on tool wear . . 71.3.5 Hard cutting surface intergrity research status . 81.3.6 Hard cutting surface intergrity research . 91.4 Content and propose of research . 13Chapter 2 Study on cutting force co

31、ntrol simulation in hard cutting . 152.1 Cutting process simulation key technolog. 152.1.1 Technical guidelines of the tool and chip . 162.1.2 Separation criteria between the tool and the workpiece . 162.2 Study on workpiece material constitutive equation . . 172.2.1 Hopkinson experimental principle

32、 and implementation . 172.2.2 The results of Hopkinson simulation experiment . 202.3 Software Isight and Abaqus joint cutting process simulation . . 232.3.1 Integerated Isight software Abaqus optimization design process . 232.3.2 Abaqus and scripting software process integation . . 242.3.3 Optimizat

33、ion problem setting . . 252.3.4 Simulation results of the output . 262.3.5 Accuracy validation of the simulation results . 272.4 Chapter Summary . 28Chapter 3 Die steel hard cutting process PCBN tool wear mechanism. 283.1 Experimental condition setting . 28Contents- IX -3.2 Study on the wear mechani

34、sm of cutter . 283.3 Study of the impact of cutting conditions on tool wear . . 313.3.1 The effects of cutting parameters on cutting tool wear . 313.3.2 The effects of nose radius of on tool wear. 333.3.3 The effects of coatings on tool wear. 333.4 Effects of tool wear on the cutting process . 343.4

35、.1 Effects of tool wear on chip generation mechanism . . 353.4.2 Effects of tool wear on the cutting force . 383.4.3 Effects of tool wear on the cutting stress and temperature field . . 403.5 Chapter Summary . 40Chapter 4 Effects of tool wear on the cutting process stability . 414.1 Cutting system modal parameter determination . 414.2 Experimental study of tool wear on the cutting stability . . 434.3 System stability studies based on spectral density RMS . 444.3.1 Theoretical study on the RMS of system stability . . 444.3.2 Experimental verification o