钛合金Ti-6A1-4V修正本构模型在高速铣削中的应用研究
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摘要
钛合金Ti-6A1-4V借助其卓越的材料性能,已成为航空、航天领域应用最为广泛的材料之一。同时,它也是一种难加工材料,高速切削技术是解决该材料大量需求与加工困难这一矛盾的重要方法。研究高速切削机理最有效的途径是切削有限元仿真,而本构模型作为切削有限元仿真的核心技术已成为国内外研究的焦点。目前广泛应用于切削有限元仿真中的Johnson-Cook (J-C)本构模型由于没有考虑动态再结晶软化效应在切削中的重大作用,在表现高温高压下的应力状态、以及绝热剪切带与切屑形态等方面时显得力不从心。本文采用理论分析、试验研究与有限元仿真相结合的方法,由钛合金Ti-6A1-4V的微观结构入手,针对J-C本构模型存在的缺陷,提出一种考虑再结晶软化效应的修正J-C本构模型,经铣削试验与有限元仿真对比研究,证明了该修正J-C本构模型更适用于钛合金Ti-6A1-4V的高速铣削过程。论文的主要研究内容如下：
(1)对钛合金Ti-6A1-4V在不同应变速率条件下的动态再结晶现象进行了系统的研究,找出了材料发生动态再结晶的条件与规律。通过对等温恒应变速率试验的动力学研究,建立了钛合金Ti-6A1-4V的Arrhenius方程和两相区变形的流动应力本构模型,证明了变形温度是材料发生再结晶的最重要因素,它与再结晶现象发生的频率成正比；对属于高应变速率范畴的高速切削进行了研究,主要是对切屑形态、绝热剪切带形态、以及切削力、表面粗糙度等进行了系统的研究,建立了切削要素、切屑形态、切削力、表面粗糙度等因素之间的关系,证明了切削过程中动态再结晶软化效应是不容忽视的。研究表明,不论在低应变速率下,还是在高应变速率下,材料均有发生动态再结晶的可能,再结晶软化效应使阻止局部塑性变形的阻力下降,加剧了材料的热塑性失稳,促进了绝热剪切带以及锯齿形切屑的产生。
(2)为解决高温高压环境下J-C本构模型不再适用于钛合金Ti-6A1-4V切削有限元仿真的问题,建立了考虑再结晶软化效应的修正J-C本构模型。通过分离式Hopkinson压杆试验(SHPB)测得了的材料应力—应变数据,并利用变量分离法拟合出修正J-C本构模型,该本构模型以临界应变值为界,以不同的表达式描述不同的应变区间。经过计算校验,该修正J-C模型可以很好地逼近SHPB试验曲线,尤其是在高温区间,修正J-C本构模型比J-C本构模型更符合SHPB实验的应力—应变曲线特征。
(3)利用子程序技术将两种本构模型嵌入到切削有限元软件AdvantEdge FEM中,通过与铣削试验的对比研究,证明了考虑再结晶软化效应的修正J-C本构模型比J-C本构模型更适用于高速铣削有限元仿真,更符合铣削的实际过程。以AdvantEdge FEM有限元软件为平台,利用增量法对本构模型进行了建模,建立了两种模型的Recht剪切失稳模型,采用回退映射应力积分算法编写了子程序,将两种本构模型嵌入到切削有限元软件中,对比研究了高速铣削时的应力特征与切屑形态。研究表明,在表现高速切削时的切屑形态变化、应力与剪切力等特征时,修正后的J-C本构模型比J-C本构模型更适用。
(4)利用网络数据库、DNC、遗传算法等技术建立了新型高速切削数据库系统,该系统集高速切削参数优化与推荐、材料本构自动生成、有限元仿真、以及刀具库管理等为一体,实现了高速切削全生命周期中参数的推荐与管理。
Ti-6A1-4V titanium alloy is often used in the aircraft industry due to the good compromise. However, this material is known to be difficult to machine. The high speed machining is one of the most effective process technologies for the contradiction between increasing machining demand and poor machining performance. The high speed machining is one of the most important approaches to the difficult-to-cut material, and the numerical simulation technology is the most effective way for the high speed machining.While the constitutive models study is the key technology in the high speed machining mechanism research. The widely used Johnson-Cook constitutive model is not suitable for Ti-6A1-4V alloy in the high-speed cutting finite element simulation; it has not response material dynamic recrystallization softening effect under high pressure and high temperature, and thus can not correctly reflect the stress state, and deformation characteristics of adiabatic shear band and serrated chips, and so on during high-speed cutting. In view of the complexity in nature, a method combining theoretical analysis with experiment and finite element simulation is proposed in this dissertation. Starting from the microscopic structure of titanium alloy Ti-6A1-4V, a new modified constitutive model of Ti-6A1-4V titanium alloy based on recrystallization is proposed considering the phenomenon during machining. The main investigation contents are listed as following:
(1)The dynamic recrystallization condition and law of Ti-6A1-4V alloy at all strain rates are investigated in the paper. The isothermal constant strain rate experiments are performed on Ti-6A1-4V alloy, which discoveried that the deformation temperature is proportional to the frequency of dynamic recrystallization, and a Arrhenius equation of Ti-6A1-4V alloy is established. It is systematically researched from the microstructure of chips, surface roughness and cutting force during the high-speed cutting. The relationship between the cutting factors, chip formation, cutting force and surface roughness is built. The research shows that it has the possibility of dynamic recrystallization at all strain rates. The plastic deformation resistance decline and the thermoplastic instabilitydue occur due to the dynamic recrystallization softening effect, and the adiabatic shearing band and serrated chip is found in the Ti-6A1-4V alloy.
(2)J-C constitutive model is inaccurate for machining simulation of titanium alloy with high temperature and heavy impact.In the paper, a new modified J-C constitutive model of Ti-6A1-4V alloy based on recrystallization softening effect is established. High-temperature SHPB (Split Hopkinson Pressure Bar) test was conducted to determine the true flow stress-strain relationship of Ti-6A1-4V alloy. With the SHPB test data, the modified constitutive model was developed by the variable separation method. The modified J-C constitutive model expresses as two expressions according to the different characteristics of material constitutive during critical strain values. The modified J-C constitutive model is proved correct and more suitable for the SHPB test curve than the J-C constitutive model, especially in the high-temperature range.
(3)A subroutine is coded and embedded in the finite element simulation software AdvantEdge FEM with the return mapping stress integration algorithm. The comparison is carried between the experimental data of milling and the simulation, and it shows that the modified J-C constitutive model is more suitable for the practical milling process. The new modified J-C constitutive model is built by the incremental method, and the the comparison is carried on of stress characteristics and chip formation in high-speed milling. It shows that the modified J-C constitutive model is more suitable than J-C constitutive when it express formation process of adiabatic shear band, chip morphology, stress and shear characteristics in the high-speed milling.
(4) A new high-speed cutting database system is established by the network database technology, DNC technology, genetic algorithms and other technical. The system combines high-speed cutting parameter optimization and recommendation, the material constitutive generated automatically, finite element simulation, as well as tool database management, which realizes the recommendation and management of the HSM parameter in its full life cycle.
(1)对钛合金Ti-6A1-4V在不同应变速率条件下的动态再结晶现象进行了系统的研究,找出了材料发生动态再结晶的条件与规律。通过对等温恒应变速率试验的动力学研究,建立了钛合金Ti-6A1-4V的Arrhenius方程和两相区变形的流动应力本构模型,证明了变形温度是材料发生再结晶的最重要因素,它与再结晶现象发生的频率成正比；对属于高应变速率范畴的高速切削进行了研究,主要是对切屑形态、绝热剪切带形态、以及切削力、表面粗糙度等进行了系统的研究,建立了切削要素、切屑形态、切削力、表面粗糙度等因素之间的关系,证明了切削过程中动态再结晶软化效应是不容忽视的。研究表明,不论在低应变速率下,还是在高应变速率下,材料均有发生动态再结晶的可能,再结晶软化效应使阻止局部塑性变形的阻力下降,加剧了材料的热塑性失稳,促进了绝热剪切带以及锯齿形切屑的产生。
(2)为解决高温高压环境下J-C本构模型不再适用于钛合金Ti-6A1-4V切削有限元仿真的问题,建立了考虑再结晶软化效应的修正J-C本构模型。通过分离式Hopkinson压杆试验(SHPB)测得了的材料应力—应变数据,并利用变量分离法拟合出修正J-C本构模型,该本构模型以临界应变值为界,以不同的表达式描述不同的应变区间。经过计算校验,该修正J-C模型可以很好地逼近SHPB试验曲线,尤其是在高温区间,修正J-C本构模型比J-C本构模型更符合SHPB实验的应力—应变曲线特征。
(3)利用子程序技术将两种本构模型嵌入到切削有限元软件AdvantEdge FEM中,通过与铣削试验的对比研究,证明了考虑再结晶软化效应的修正J-C本构模型比J-C本构模型更适用于高速铣削有限元仿真,更符合铣削的实际过程。以AdvantEdge FEM有限元软件为平台,利用增量法对本构模型进行了建模,建立了两种模型的Recht剪切失稳模型,采用回退映射应力积分算法编写了子程序,将两种本构模型嵌入到切削有限元软件中,对比研究了高速铣削时的应力特征与切屑形态。研究表明,在表现高速切削时的切屑形态变化、应力与剪切力等特征时,修正后的J-C本构模型比J-C本构模型更适用。
(4)利用网络数据库、DNC、遗传算法等技术建立了新型高速切削数据库系统,该系统集高速切削参数优化与推荐、材料本构自动生成、有限元仿真、以及刀具库管理等为一体,实现了高速切削全生命周期中参数的推荐与管理。
Ti-6A1-4V titanium alloy is often used in the aircraft industry due to the good compromise. However, this material is known to be difficult to machine. The high speed machining is one of the most effective process technologies for the contradiction between increasing machining demand and poor machining performance. The high speed machining is one of the most important approaches to the difficult-to-cut material, and the numerical simulation technology is the most effective way for the high speed machining.While the constitutive models study is the key technology in the high speed machining mechanism research. The widely used Johnson-Cook constitutive model is not suitable for Ti-6A1-4V alloy in the high-speed cutting finite element simulation; it has not response material dynamic recrystallization softening effect under high pressure and high temperature, and thus can not correctly reflect the stress state, and deformation characteristics of adiabatic shear band and serrated chips, and so on during high-speed cutting. In view of the complexity in nature, a method combining theoretical analysis with experiment and finite element simulation is proposed in this dissertation. Starting from the microscopic structure of titanium alloy Ti-6A1-4V, a new modified constitutive model of Ti-6A1-4V titanium alloy based on recrystallization is proposed considering the phenomenon during machining. The main investigation contents are listed as following:
(1)The dynamic recrystallization condition and law of Ti-6A1-4V alloy at all strain rates are investigated in the paper. The isothermal constant strain rate experiments are performed on Ti-6A1-4V alloy, which discoveried that the deformation temperature is proportional to the frequency of dynamic recrystallization, and a Arrhenius equation of Ti-6A1-4V alloy is established. It is systematically researched from the microstructure of chips, surface roughness and cutting force during the high-speed cutting. The relationship between the cutting factors, chip formation, cutting force and surface roughness is built. The research shows that it has the possibility of dynamic recrystallization at all strain rates. The plastic deformation resistance decline and the thermoplastic instabilitydue occur due to the dynamic recrystallization softening effect, and the adiabatic shearing band and serrated chip is found in the Ti-6A1-4V alloy.
(2)J-C constitutive model is inaccurate for machining simulation of titanium alloy with high temperature and heavy impact.In the paper, a new modified J-C constitutive model of Ti-6A1-4V alloy based on recrystallization softening effect is established. High-temperature SHPB (Split Hopkinson Pressure Bar) test was conducted to determine the true flow stress-strain relationship of Ti-6A1-4V alloy. With the SHPB test data, the modified constitutive model was developed by the variable separation method. The modified J-C constitutive model expresses as two expressions according to the different characteristics of material constitutive during critical strain values. The modified J-C constitutive model is proved correct and more suitable for the SHPB test curve than the J-C constitutive model, especially in the high-temperature range.
(3)A subroutine is coded and embedded in the finite element simulation software AdvantEdge FEM with the return mapping stress integration algorithm. The comparison is carried between the experimental data of milling and the simulation, and it shows that the modified J-C constitutive model is more suitable for the practical milling process. The new modified J-C constitutive model is built by the incremental method, and the the comparison is carried on of stress characteristics and chip formation in high-speed milling. It shows that the modified J-C constitutive model is more suitable than J-C constitutive when it express formation process of adiabatic shear band, chip morphology, stress and shear characteristics in the high-speed milling.
(4) A new high-speed cutting database system is established by the network database technology, DNC technology, genetic algorithms and other technical. The system combines high-speed cutting parameter optimization and recommendation, the material constitutive generated automatically, finite element simulation, as well as tool database management, which realizes the recommendation and management of the HSM parameter in its full life cycle.
引文
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