外圆磨削表面强化技术的试验研究与理论分析
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摘要
磨削表面强化技术利用磨削过程中生成的磨削热使工件表层温度瞬间升高到Ac3以上,然后迅速冷却,以使表层材料马氏体化。该技术集成了磨削加工工艺与表面热处理工艺,可以有效缩短产品生产周期、提高生产效率、降低制造成本,具有显著的经济价值和社会效益。
本文采用了40Cr钢与45号钢两种材料进行了外圆单程切入式磨削表面强化技术的试验研究,并对强化试件进行了金相组织观测与硬度分布测量。结果表明工件表层材料的金相组织由外至内依次分为强化层、过渡层与基体三部分,组织成分分别为马氏体、马氏体与铁素体混合物、铁素体与珠光体混合物。在本试验条件下,工件表面硬度值最高为HV824.1,硬化厚度最高为1.1mm,达到了与高频淬火相同的强化效果。采用了不同的磨削深度、工件速度和砂轮特性进行外圆磨削表面强化效果的正交试验,并对硬化厚度和表面硬度两项指标进行了分析,以研究各因素对强化效果的影响程度及影响规律。结果表明,对于硬化层厚度,三项因素的影响显著程度依次为磨削深度、工件速度、砂轮特性,硬化厚度值随磨削深度增加而增大、随工件速度增加先增大后减小、采用白刚玉砂轮的硬化厚度大于铬刚玉而且小磨粒粒度号砂轮的硬化厚度大于大磨粒粒度号砂轮。对于表面硬度,仅磨削深度具有较显著影响,硬度值随磨削深度的增加而增大。在本文试验条件下采用0.4mm的磨削深度、0.5m/s的工件速度、WA46L8V砂轮进行外圆磨削表面强化,可以兼顾较深的硬化层厚度与较高的表面硬度,获得最佳的试件表面综合强化效果。
对比40Cr钢与45号钢两种不同材料工件的强化效果,发现两种材料在同等的磨削参数与条件下,外圆磨削的表面强化效果与各因素的影响规律相似。但40Cr钢硬化厚度大于45号钢;45号钢的表面硬度高于40Cr钢。这种差异源于材料特性。对外圆磨削表面强化过程中砂轮二次经过的重叠强化区进行了金相观测与硬度分布测量。结果表明,该区域内经历的重叠强化过程实质上为二次淬火,其金相组织与硬度分布没有发生明显变化。砂轮退刀后工件表面上的残留热量沿砂轮移动方向继续传递,造成了重叠强化区尾部的工件表面硬度下降并伴随少量的回火索氏体出现。但由于其尺寸较小(1.0mm)而且最低硬度值HV479.6仍满足工件的硬度要求,因此对整体强化效果没有显著影响。
对已强化试件进行了精磨以满足表面粗糙度与加工质量要求,并对精磨结果进行研究。结果表明,试件的金相组织与表层硬度分布并没有受到精磨过程的影响,通过合理选取磨削参数与条件,外圆磨削表面强化技术可以同时满足工件表面的硬度要求与加工精度要求。
采用测力顶尖与红外测温仪,在强化试验过程中采集了磨削力与磨削温度数据,为后续的理论分析提供了依据。在此基础上,针对磨削力与磨削温度的变化规律与影响因素进行了研究。研究表明,外圆磨削表面强化中的磨削力与工件速度、磨削深度均呈现正比关系,法向分力与切向分力之比远大于普通磨削情况;而磨削温度的影响因素按显著程度依次为磨削深度、砂轮特性、工件速度,影响规律均与对硬化厚度的影响规律相同。
深入研究了强化过程的切削机理,利用切削过程中的单颗磨粒能量消耗,并结合磨粒分布情况,提出了外圆磨削表面强化过程中磨削力的计算方法。在此基础上考虑了磨粒对材料的耕犁作用,以及磨粒对材料的大切深情况,使得计算结果更加准确。将磨削力的计算结果与试验中的实测值对比,发现二者具有较好的一致性。
充分考虑了磨除工件材料的不同阶段,建立了外圆磨削表面强化过程的复合型热源模型与热量分配比模型。并进一步研究了磨削条件对热量分配比的影响规律。研究表明,在诸多因素中,磨粒粒度与砂轮线速度对工件表面的热量分配比影响最为显著。磨粒粒度号增大,传入工件表面的热量减少;砂轮线速度增加,传入工件表面的热量增加。
采用ANSYS软件对外圆磨削表面强化过程进行了仿真。研究了强化过程中温度场的动态分布与时变情况,以及工件模型中不同位置点的温度变化情况。研究表明,磨削温度的仿真结果与测量值有较好的一致性,表明仿真结果有效可靠、建立的热源模型准确合理。在试验不便进行时,可以利用仿真方法进行研究分析。
Grind-hardening is a new technology which utilizes grinding heat to induce martensitic phase transformation and strengthen workpiece surface in gringding process by raising surface temperature above Ac3 instantaneously and cooling quickly. The application of this new technology can reduce production cycle, improve working efficiency, and decrease manufacturing cost by integrating the two operations of grinding and surface heat treatment into one, which has the great social and economical benefits.
Grind-hardening experiments for external grinding mode are carried out. The results indicate that the hardened workpiece surface consists of three parts of hardened layer, transition layer, and body. The metallurgical structures of the parts are martensite, mixture of martensite and ferrite, and mixture of ferrite and pearlite respectively. Under the experiment condition, the top value of hardness and hardened depth is HV824.1 and 1.1mm respectively, which achieves the effect of high-frequency hardening.
The orthogonal experiments with different cut depths, workpiece speeds and wheel characteristic are performed, contribution and pattern of the factors’influence to hardening effect are analyzed. The results show that hardened layer thickness rises with increasing cut depth, and rises and falls with increasing workpiece speed. White alundum wheel increased more hardened layer thickness than pink alundum, while small grain granularity products more hardened layer thickness than big one. The order of factors is cut depth, workpiece speed, and wheel characteristic according to the contribution. The results also indicate that surface hardness is only affected by cut depth, and the hardness value rises with increasing cut depth. Under the present experiment condition, the adoption of 0.4mm cut depth, 0.5m/s workpiece speed and wheel WA46L8V may achieve good comprehensive grind-hardening results of both hardened layer thickness and surface hardness.
40Cr steel and 45 steel are adopted simultaneously in the experiments to research hardening effects with different materials. The results show good hardened effectiveness of both materials as well as the similar pattern of metallurgical structure and hardness distribution. It has been found that 40Cr steel has more hardened layer thickness while 45 steel has higher surface hardness. The difference derives from the material property.
The obsevation of the metallurgical structure and test of hardness distribution for the overlap hardened zone demonstrate the rehardening is occurred and the metallurgical structure or hardness distribution changes little. Due to the inertance of conductivity, the residual heat in the zone tempered the material at its end part. A little tempered sorbite appears while the hardness value drops accordingly. However, because the tempered area is small in size (1.0mm) and even the bottom value (HV479.6) can satisfy the hardness requirement, it has little influence to the total hardened effectiveness.
Fine grinding stage is taken for the surface roughness and quality after the hardened layer is obtained in the coarse grinding stage, and the fine grinded sample is analyzed. The result indicates the same metallurgical structures and surface hardness to the sample of coarse stage. Therefore, with rational choiced grinding parameters and condition, requirement of surface hardness and machining precision may be met simultaneously.
Grinding force and temperature are measured in the experiments by adopting elastic core clampers and infrared thermometer, which provides data for theory study. Moreover, the variation regularity and influence factors are analyzed. The results indicate that grindng force is proportional to workpiece speed and cut depth in external grind-hardening process, and the ratio of normal force to tangential force is more than that of common grinding. Grinding temperature is influenced by cut depth, wheel characteristics and workpiece speed in the contribution order, and has the same change regularity of hardened layer thickness.
Calculation equations of grinding force for external grind-hardening are derived through the study of grain cutting mechanism and the utilization of grain energy cost and distribution. Plough stage and large cut depth of grain are considered for accurate results. It has been shown that the calculation results have consistency with measurment results.
Process of material remove is considered to consist of various stages. The compound heat and heat distribution ratio are modelled for the whole process. Moreover, the influence pattern of grinding condition to distribution of heat is evaluated. The results demonstrate that grain granularity and wheel velocity are the major factors. Both increasing grain granularity number and decreasing wheel velocity may reduce the heat conducted into workpiece surface.
A computational finite element method software, ANSYS, is introduced to simulate the process of external grind-hardening. The dynamic states of temperature field and temperature history of points in various model placements are investigated by simulation. It has been demonstrated that the simulation results are in accordance with measurment results due to the reliable simulation method and the accurate heat model. Therefore the simulation may be studied instead of experiment.
本文采用了40Cr钢与45号钢两种材料进行了外圆单程切入式磨削表面强化技术的试验研究,并对强化试件进行了金相组织观测与硬度分布测量。结果表明工件表层材料的金相组织由外至内依次分为强化层、过渡层与基体三部分,组织成分分别为马氏体、马氏体与铁素体混合物、铁素体与珠光体混合物。在本试验条件下,工件表面硬度值最高为HV824.1,硬化厚度最高为1.1mm,达到了与高频淬火相同的强化效果。采用了不同的磨削深度、工件速度和砂轮特性进行外圆磨削表面强化效果的正交试验,并对硬化厚度和表面硬度两项指标进行了分析,以研究各因素对强化效果的影响程度及影响规律。结果表明,对于硬化层厚度,三项因素的影响显著程度依次为磨削深度、工件速度、砂轮特性,硬化厚度值随磨削深度增加而增大、随工件速度增加先增大后减小、采用白刚玉砂轮的硬化厚度大于铬刚玉而且小磨粒粒度号砂轮的硬化厚度大于大磨粒粒度号砂轮。对于表面硬度,仅磨削深度具有较显著影响,硬度值随磨削深度的增加而增大。在本文试验条件下采用0.4mm的磨削深度、0.5m/s的工件速度、WA46L8V砂轮进行外圆磨削表面强化,可以兼顾较深的硬化层厚度与较高的表面硬度,获得最佳的试件表面综合强化效果。
对比40Cr钢与45号钢两种不同材料工件的强化效果,发现两种材料在同等的磨削参数与条件下,外圆磨削的表面强化效果与各因素的影响规律相似。但40Cr钢硬化厚度大于45号钢;45号钢的表面硬度高于40Cr钢。这种差异源于材料特性。对外圆磨削表面强化过程中砂轮二次经过的重叠强化区进行了金相观测与硬度分布测量。结果表明,该区域内经历的重叠强化过程实质上为二次淬火,其金相组织与硬度分布没有发生明显变化。砂轮退刀后工件表面上的残留热量沿砂轮移动方向继续传递,造成了重叠强化区尾部的工件表面硬度下降并伴随少量的回火索氏体出现。但由于其尺寸较小(1.0mm)而且最低硬度值HV479.6仍满足工件的硬度要求,因此对整体强化效果没有显著影响。
对已强化试件进行了精磨以满足表面粗糙度与加工质量要求,并对精磨结果进行研究。结果表明,试件的金相组织与表层硬度分布并没有受到精磨过程的影响,通过合理选取磨削参数与条件,外圆磨削表面强化技术可以同时满足工件表面的硬度要求与加工精度要求。
采用测力顶尖与红外测温仪,在强化试验过程中采集了磨削力与磨削温度数据,为后续的理论分析提供了依据。在此基础上,针对磨削力与磨削温度的变化规律与影响因素进行了研究。研究表明,外圆磨削表面强化中的磨削力与工件速度、磨削深度均呈现正比关系,法向分力与切向分力之比远大于普通磨削情况;而磨削温度的影响因素按显著程度依次为磨削深度、砂轮特性、工件速度,影响规律均与对硬化厚度的影响规律相同。
深入研究了强化过程的切削机理,利用切削过程中的单颗磨粒能量消耗,并结合磨粒分布情况,提出了外圆磨削表面强化过程中磨削力的计算方法。在此基础上考虑了磨粒对材料的耕犁作用,以及磨粒对材料的大切深情况,使得计算结果更加准确。将磨削力的计算结果与试验中的实测值对比,发现二者具有较好的一致性。
充分考虑了磨除工件材料的不同阶段,建立了外圆磨削表面强化过程的复合型热源模型与热量分配比模型。并进一步研究了磨削条件对热量分配比的影响规律。研究表明,在诸多因素中,磨粒粒度与砂轮线速度对工件表面的热量分配比影响最为显著。磨粒粒度号增大,传入工件表面的热量减少;砂轮线速度增加,传入工件表面的热量增加。
采用ANSYS软件对外圆磨削表面强化过程进行了仿真。研究了强化过程中温度场的动态分布与时变情况,以及工件模型中不同位置点的温度变化情况。研究表明,磨削温度的仿真结果与测量值有较好的一致性,表明仿真结果有效可靠、建立的热源模型准确合理。在试验不便进行时,可以利用仿真方法进行研究分析。
Grind-hardening is a new technology which utilizes grinding heat to induce martensitic phase transformation and strengthen workpiece surface in gringding process by raising surface temperature above Ac3 instantaneously and cooling quickly. The application of this new technology can reduce production cycle, improve working efficiency, and decrease manufacturing cost by integrating the two operations of grinding and surface heat treatment into one, which has the great social and economical benefits.
Grind-hardening experiments for external grinding mode are carried out. The results indicate that the hardened workpiece surface consists of three parts of hardened layer, transition layer, and body. The metallurgical structures of the parts are martensite, mixture of martensite and ferrite, and mixture of ferrite and pearlite respectively. Under the experiment condition, the top value of hardness and hardened depth is HV824.1 and 1.1mm respectively, which achieves the effect of high-frequency hardening.
The orthogonal experiments with different cut depths, workpiece speeds and wheel characteristic are performed, contribution and pattern of the factors’influence to hardening effect are analyzed. The results show that hardened layer thickness rises with increasing cut depth, and rises and falls with increasing workpiece speed. White alundum wheel increased more hardened layer thickness than pink alundum, while small grain granularity products more hardened layer thickness than big one. The order of factors is cut depth, workpiece speed, and wheel characteristic according to the contribution. The results also indicate that surface hardness is only affected by cut depth, and the hardness value rises with increasing cut depth. Under the present experiment condition, the adoption of 0.4mm cut depth, 0.5m/s workpiece speed and wheel WA46L8V may achieve good comprehensive grind-hardening results of both hardened layer thickness and surface hardness.
40Cr steel and 45 steel are adopted simultaneously in the experiments to research hardening effects with different materials. The results show good hardened effectiveness of both materials as well as the similar pattern of metallurgical structure and hardness distribution. It has been found that 40Cr steel has more hardened layer thickness while 45 steel has higher surface hardness. The difference derives from the material property.
The obsevation of the metallurgical structure and test of hardness distribution for the overlap hardened zone demonstrate the rehardening is occurred and the metallurgical structure or hardness distribution changes little. Due to the inertance of conductivity, the residual heat in the zone tempered the material at its end part. A little tempered sorbite appears while the hardness value drops accordingly. However, because the tempered area is small in size (1.0mm) and even the bottom value (HV479.6) can satisfy the hardness requirement, it has little influence to the total hardened effectiveness.
Fine grinding stage is taken for the surface roughness and quality after the hardened layer is obtained in the coarse grinding stage, and the fine grinded sample is analyzed. The result indicates the same metallurgical structures and surface hardness to the sample of coarse stage. Therefore, with rational choiced grinding parameters and condition, requirement of surface hardness and machining precision may be met simultaneously.
Grinding force and temperature are measured in the experiments by adopting elastic core clampers and infrared thermometer, which provides data for theory study. Moreover, the variation regularity and influence factors are analyzed. The results indicate that grindng force is proportional to workpiece speed and cut depth in external grind-hardening process, and the ratio of normal force to tangential force is more than that of common grinding. Grinding temperature is influenced by cut depth, wheel characteristics and workpiece speed in the contribution order, and has the same change regularity of hardened layer thickness.
Calculation equations of grinding force for external grind-hardening are derived through the study of grain cutting mechanism and the utilization of grain energy cost and distribution. Plough stage and large cut depth of grain are considered for accurate results. It has been shown that the calculation results have consistency with measurment results.
Process of material remove is considered to consist of various stages. The compound heat and heat distribution ratio are modelled for the whole process. Moreover, the influence pattern of grinding condition to distribution of heat is evaluated. The results demonstrate that grain granularity and wheel velocity are the major factors. Both increasing grain granularity number and decreasing wheel velocity may reduce the heat conducted into workpiece surface.
A computational finite element method software, ANSYS, is introduced to simulate the process of external grind-hardening. The dynamic states of temperature field and temperature history of points in various model placements are investigated by simulation. It has been demonstrated that the simulation results are in accordance with measurment results due to the reliable simulation method and the accurate heat model. Therefore the simulation may be studied instead of experiment.
引文
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