置氢钛合金高效切削仿真及刀具磨损预测研究
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摘要
钛合金以其优越的综合性能日益广泛的应用于航空航天及民用工业，然而钛合金高效切削时刀具的快速磨损制约了它进一步的推广应用，因此，如何改善和提高钛合金的切削加工性一直是钛合金切削加工研究的热点。钛合金的置氢处理技术是通过置氢的方式改变钛合金的组织结构进而改善其切削加工性的一种新工艺，为钛合金的高效加工提供了一种新途径。本文在国家自然科学基金(50775115)资助下，借助有限元软件并结合相关实验，建立了置氢钛合金高效切削仿真模型及刀具磨损预测模型，探讨了高效切削下置氢钛合金的切削加工性，分析了置氢对钛合金切削加工性的影响规律，研究了置氢量对刀具耐用度的影响规律及作用机理。主要研究内容如下：
1.对置氢钛合金切削仿真中所涉及的关键技术进行了研究。
(1)研究了置氢钛合金在高温、高应变率下的动态力学性能。采用分离式霍普金森压杆和材料试验机进行了置氢钛合金动态及准静态力学性能试验，获取了高温、高应变率下的动态力学性能。对Johnson-Cook(J-C)本构模型进行了改进，建立了置氢钛合金的塑性本构方程。
(2)研究了适用于置氢钛合金切削仿真过程单元删除的断裂准则。借助于钛合金压缩实验及有限元仿真，对常用的几种韧性断裂准则进行了比较，发现以孔洞理论为基础的Oyane准则较适合于切削过程。并通过压缩实验，获取了置氢钛合金Oyane准则中的相关参数值。
(3)通过研制的弹簧加载恒力平台进行了高速、大载荷下硬质合金与置氢钛合金间的摩擦实验，建立了包含温度及载荷的摩擦经验公式。测量和分析了载荷、温度及滑动速度等对滑动摩擦系数的影响，得出了包含载荷及温度在内的滑动摩擦经验公式。
2.通过建立的置氢钛合金切削仿真模型，对高效切削置氢钛合金的切削过程进行了仿真。并通过实验对切削力、切削温度及切屑形态等仿真结果进行了验证。
3.探讨了切削置氢钛合金时刀具的磨损形态及磨损机理。借助光学显微镜、SEM及EDS等仪器，分析了切削(车、铣)刀具的磨损形态，研究了切削置氢钛合金时刀具的磨损机理，分析了置氢对钛合金切削加工性的改善作用。
4.建立了新的刀具磨损率模型。根据刀具的磨损机理，该模型充分反映切削置氢钛合金时刀具的磨粒、粘结及扩散磨损。通过采取增大刀-屑间传热系数、节点移动及边界光滑处理等方法，解决了刀具温度场不稳定、刀具磨损形貌变化及刀具单元畸变等一系列问题，建立了刀具磨损仿真有限元模型，并对仿真结果进行了实验验证。
5.通过建立的刀具磨损预测有限元模型，对置氢钛合金高效切削时刀具的磨损情况进行了预测。对切削过程中不同磨损机理所占比重进行了定量分析，确定了主要的磨损机理及其随切削过程的变化趋势。通过对比，揭示了置氢的作用机理及置氢提高刀具耐用度的根本原因。通过研究切削参数对刀具磨损的影响规律，给出了高效切削置氢钛合金切削参数的合理选择范围。最后分析了刀具磨损对切屑形貌、切削力、切削温度及刀具所受应力的影响规律。
Titanium alloy are widely used in aeronautics and aerospace industry, and civil applications as wellowing to its excellent mechanical properties. However, the poor machinability and the induced rapidtool wear during cutting has limits the further wide application of titanium alloy. Therefore, how toimprove the machinability of titanium alloy has been drawn much attention. In recent year,thermohydrogen treatment technique has provided a potential way to realize the high efficiencycutting of titanium alloy because this special technique could change the microstructure of titaniumalloy. Supported by National Natural Science Foundation of China (50775115), the high-efficiencycutting mechanism and the tool wear behavior are investigated using the finite element simulationmethods. Particularly, the machinability of hydrogenated titanium alloy is studied under thehigh-efficiency cutting circumstance. The influence of the hydrogen content on the titanium alloymachinability and the tool wear are discussed.
The major research work is as follows:
1. Several key factors in finite element simulation of the cutting process of the hydrogenatedtitanium alloy are investigated.
(1) The static and dynamic compression experiments of hydrogenated titanium alloys are carriedout with the material testing machine and split Hopkinson pressure bar (SHPB). The stress-straincurves are obtained at high temperature and high strain rate. The modified Johnson-Cook(J-C)constitutive relations of hydrogenated titanium alloy are derived.
(2) The ductile fracture criterion, which is suitable to the cutting process is studied. Fourcommon ductile fracture criterions are compared each other depending on non-linear FEM softwareand compression tests of titanium alloy. The results reveal that the Oyane ctirerion based on cracktheory is suitable to describe the cutting process of hydrogenated titaium alloy. Furthermore, theconstant parameters in Oyane criterion of all hydrogenated titanium alloys are calculated. The resultsare proven valid in the cutting experiments.
(3) The friction laws between cutting tool and hydrogenated titanium alloy are analyzed. Theconstant force test platform is designed and applied to simulate the sliding zone of Zorev’s frictionmodel. The sliding friction efficient is measured and compared under different loads, temperature andsliding velocity. The sliding friction laws are therefore obtained.
2. The FEM models of the cutting process of the hydrogenated titanium alloy are established. Thesimulated cutting force, cutting temperature and chip morphology are compared with the experimental ones. Furthermore, the FEM models are utilized to simulate the high efficiency cutting process of thehydrogenated titanium alloy.
3. The tool wear mechanism is studied during cutting the hydrogenated titanium alloy with opticalmicroscope and scanning electron microscope. At the same time, the relationship between tool lifeand cutting parameters were investigated. The results show that the hydrogenation could improve themachinability of Ti6Al4V alloy.
4. The wear rate models concerning different wear mechanism are built according to the wearexperimental results, which include abrasive wear, adhesive wear and diffusion wear. Then the FEMmodel of tool wear simulation is presented. Several problems of tool wear simulation, i.e. predictionof temperature distribution, the updating of tool geometry and the smoothing of wear boundary of toolare presented and discussed. The reasonable prediction of the tool wear is proven feasible in thecutting experiments.
5. The tool wear behavior is simulated during cutting hydrogenated titanium based on theestablished finite element model. The effect of cutting parameters on tool wear is investigated. Theexact proportion of different wear mechanism is determined according to the simulation results., Thedominate wear mechanism and the corresponding changing tendency in the cutting process isanalyzed. Moreover, based on the experiment and simulation results, the mechanism of hydrogenationon improving titanium’s machinability is discussed. The reasonable range of the cutting parametersduring high efficiency cutting hydrogenated titanium alloy is provided. Finally, the influence of toolwear on chip morphology, cutting temperature, cutting force and tool stress are investigated.
1.对置氢钛合金切削仿真中所涉及的关键技术进行了研究。
(1)研究了置氢钛合金在高温、高应变率下的动态力学性能。采用分离式霍普金森压杆和材料试验机进行了置氢钛合金动态及准静态力学性能试验，获取了高温、高应变率下的动态力学性能。对Johnson-Cook(J-C)本构模型进行了改进，建立了置氢钛合金的塑性本构方程。
(2)研究了适用于置氢钛合金切削仿真过程单元删除的断裂准则。借助于钛合金压缩实验及有限元仿真，对常用的几种韧性断裂准则进行了比较，发现以孔洞理论为基础的Oyane准则较适合于切削过程。并通过压缩实验，获取了置氢钛合金Oyane准则中的相关参数值。
(3)通过研制的弹簧加载恒力平台进行了高速、大载荷下硬质合金与置氢钛合金间的摩擦实验，建立了包含温度及载荷的摩擦经验公式。测量和分析了载荷、温度及滑动速度等对滑动摩擦系数的影响，得出了包含载荷及温度在内的滑动摩擦经验公式。
2.通过建立的置氢钛合金切削仿真模型，对高效切削置氢钛合金的切削过程进行了仿真。并通过实验对切削力、切削温度及切屑形态等仿真结果进行了验证。
3.探讨了切削置氢钛合金时刀具的磨损形态及磨损机理。借助光学显微镜、SEM及EDS等仪器，分析了切削(车、铣)刀具的磨损形态，研究了切削置氢钛合金时刀具的磨损机理，分析了置氢对钛合金切削加工性的改善作用。
4.建立了新的刀具磨损率模型。根据刀具的磨损机理，该模型充分反映切削置氢钛合金时刀具的磨粒、粘结及扩散磨损。通过采取增大刀-屑间传热系数、节点移动及边界光滑处理等方法，解决了刀具温度场不稳定、刀具磨损形貌变化及刀具单元畸变等一系列问题，建立了刀具磨损仿真有限元模型，并对仿真结果进行了实验验证。
5.通过建立的刀具磨损预测有限元模型，对置氢钛合金高效切削时刀具的磨损情况进行了预测。对切削过程中不同磨损机理所占比重进行了定量分析，确定了主要的磨损机理及其随切削过程的变化趋势。通过对比，揭示了置氢的作用机理及置氢提高刀具耐用度的根本原因。通过研究切削参数对刀具磨损的影响规律，给出了高效切削置氢钛合金切削参数的合理选择范围。最后分析了刀具磨损对切屑形貌、切削力、切削温度及刀具所受应力的影响规律。
Titanium alloy are widely used in aeronautics and aerospace industry, and civil applications as wellowing to its excellent mechanical properties. However, the poor machinability and the induced rapidtool wear during cutting has limits the further wide application of titanium alloy. Therefore, how toimprove the machinability of titanium alloy has been drawn much attention. In recent year,thermohydrogen treatment technique has provided a potential way to realize the high efficiencycutting of titanium alloy because this special technique could change the microstructure of titaniumalloy. Supported by National Natural Science Foundation of China (50775115), the high-efficiencycutting mechanism and the tool wear behavior are investigated using the finite element simulationmethods. Particularly, the machinability of hydrogenated titanium alloy is studied under thehigh-efficiency cutting circumstance. The influence of the hydrogen content on the titanium alloymachinability and the tool wear are discussed.
The major research work is as follows:
1. Several key factors in finite element simulation of the cutting process of the hydrogenatedtitanium alloy are investigated.
(1) The static and dynamic compression experiments of hydrogenated titanium alloys are carriedout with the material testing machine and split Hopkinson pressure bar (SHPB). The stress-straincurves are obtained at high temperature and high strain rate. The modified Johnson-Cook(J-C)constitutive relations of hydrogenated titanium alloy are derived.
(2) The ductile fracture criterion, which is suitable to the cutting process is studied. Fourcommon ductile fracture criterions are compared each other depending on non-linear FEM softwareand compression tests of titanium alloy. The results reveal that the Oyane ctirerion based on cracktheory is suitable to describe the cutting process of hydrogenated titaium alloy. Furthermore, theconstant parameters in Oyane criterion of all hydrogenated titanium alloys are calculated. The resultsare proven valid in the cutting experiments.
(3) The friction laws between cutting tool and hydrogenated titanium alloy are analyzed. Theconstant force test platform is designed and applied to simulate the sliding zone of Zorev’s frictionmodel. The sliding friction efficient is measured and compared under different loads, temperature andsliding velocity. The sliding friction laws are therefore obtained.
2. The FEM models of the cutting process of the hydrogenated titanium alloy are established. Thesimulated cutting force, cutting temperature and chip morphology are compared with the experimental ones. Furthermore, the FEM models are utilized to simulate the high efficiency cutting process of thehydrogenated titanium alloy.
3. The tool wear mechanism is studied during cutting the hydrogenated titanium alloy with opticalmicroscope and scanning electron microscope. At the same time, the relationship between tool lifeand cutting parameters were investigated. The results show that the hydrogenation could improve themachinability of Ti6Al4V alloy.
4. The wear rate models concerning different wear mechanism are built according to the wearexperimental results, which include abrasive wear, adhesive wear and diffusion wear. Then the FEMmodel of tool wear simulation is presented. Several problems of tool wear simulation, i.e. predictionof temperature distribution, the updating of tool geometry and the smoothing of wear boundary of toolare presented and discussed. The reasonable prediction of the tool wear is proven feasible in thecutting experiments.
5. The tool wear behavior is simulated during cutting hydrogenated titanium based on theestablished finite element model. The effect of cutting parameters on tool wear is investigated. Theexact proportion of different wear mechanism is determined according to the simulation results., Thedominate wear mechanism and the corresponding changing tendency in the cutting process isanalyzed. Moreover, based on the experiment and simulation results, the mechanism of hydrogenationon improving titanium’s machinability is discussed. The reasonable range of the cutting parametersduring high efficiency cutting hydrogenated titanium alloy is provided. Finally, the influence of toolwear on chip morphology, cutting temperature, cutting force and tool stress are investigated.
引文
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