陶瓷结合剂金刚石砂轮高速磨削硬质合金的机理研究
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摘要
硬质合金是一种有别于较软的金属材料和硬脆陶瓷材料的混合硬碳化物和软金属相的硬脆复合材料。材料中软金属相以及硬质相含量的不同，使得材料的微细结构各异，导致硬质合金磨削性能大为不同。硬质合金优异的物理机械性能有助于该类材料在工程中的应用，但高硬度、高耐磨损的性能也使得对它的磨削加工变得非常困难。本课题旨在将高速磨削工艺应用于硬质合金加工，深入研究硬质合金磨削机理和高速磨削的磨削机制，为该难题的解决提供有效方案、实验基础以及理论依据。国内外学者较少在硬质合金高速磨削机理上做相关的研究。因此，本课题进行了陶瓷结合剂金刚石砂轮高速磨削（最高砂轮线速度达120m/s）硬质合金磨削机理的实验研究。论文的主要研究工作概括如下：
1．本文采用陶瓷结合剂金刚石砂轮分别对五种显微结构和物理性能上具有独特特征的硬质合金进行大量的高速磨削实验。测量了不同加工参数下（砂轮线速度、磨削深度和工件速度）的磨削力。分析了加工参数、单颗磨粒最大未变形切屑厚度、切削长度和材料的物理机械性能对单位宽度磨削力、力比、单颗磨粒承受的磨削力、磨削比能大小的影响。研究发现磨削力和磨削比能与单颗磨粒最大未变形切屑厚度、切削长度、材料的物理机械性能和材料去除方式有关。利用最小二乘法拟合高速磨削实验数据，建立了磨削力和磨削比能与单颗磨粒最大未变形切屑厚度、切削长度的回归关系模型。通过分析磨削比能的分配机理表明，磨削过程中，大部分磨削能量消耗于金刚石磨粒对硬质合金的滑擦与塑性耕犁，单位宽度磨削功率Pm与单位时间单位宽度内金刚石颗粒耕犁面积Sw有很好的线性关系。与低速度磨削相比，高速磨削的磨削力和单颗磨粒承受的磨削力明显减小，而磨削力比和磨削比能增大。
2．通过夹丝热电偶测量不同加工参数下磨削温度，使用温度拟合的方法估算热量分配比例。综合研究了不同加工参数及不同硬质合金类型对磨削弧区的温度特征以及传入工件的热量分配比例特征的影响。由于砂轮与工件接触区的热流密度与未变形切屑厚度有关，因此假设接触弧区中流入工件的热源分布为抛物线分布。用有限元的方法对温度场进行三维仿真，研究工件的热负荷引起的瞬态温度场。仿真表明，用抛物线热流分布比三角形热流分布更有说服力。仿真结果与实验结果进行了对比，验证了仿真结果的合理性。根据仿真获得的温度分布情况，可以预测工件的热影响程度。在湿磨条件下，顺磨五种硬质合金弧区温度低于185℃。热量分配比例随切深、砂轮线速度的增加和工件进给速度的减少而下降。通过温度拟合方法获得的热量分配比例在2.4%-14%范围之间。与低速度磨削相比，高速磨削的磨削温度升高，而热量分配比例下降。
3．测量了不同加工参数下振动加速度信号以及磨削后工件的表面粗糙度和观察磨削后的表面形貌。研究了磨削振动特性和工件表面形貌特征，并用自回归三谱切片评估磨削表面特征的方法表征振动与表面粗糙度之间的关系。探讨了陶瓷结合剂金刚石砂轮高速磨削硬质合金的磨削机理。高速磨削时，振动加速度的幅值明显增大，并会导致磨削表面产生裂纹，影响磨削表面质量。磨削表面质量与加工条件、材料的去除方式、材料的显微结构和物理特性有关。表面粗糙度随磨削深度、工件进给速度、碳化钨颗粒度的增加而增大，随砂轮线速度增加而减小。通过最小二乘法拟合表面粗糙度数据，发现磨削三要素中，工件进给速度对表面粗糙度影响最大。表面粗糙度值随单颗磨粒最大未变形切屑厚度增加而单调递增。对比五种硬质合金材料磨削后的表面粗糙度表明，高速磨削更有利于脆性大的材料降低表面粗糙度值。硬质合金磨削表面形貌的观察表明，磨削加工过程中工件材料以脆性断裂和塑性去除两种方式去除。钨钴类硬质合金主要以塑性方式去除材料，钨钛钴类硬质合金（YT30）主要以脆性断裂的方式去除。
Cemented carbide is a kind of hard and brittle composite material which is a hybridof hard carbide and soft metal phase, and different from soft metal materials and hardand brittle ceramic material. The combination of hard particles in a relative ductilematrix leads to different materials micro-structure. It leads to different grindingperformance. Due to their excellent mechanical properties, such as high strength, highhardness and high wear resistance, cement carbide materials have been widely used inthe engineering fields where high wear resistance and thermal stability are required.Although the preeminent mechanical properties of cement carbides facilitate theirwide applications, they also render a challenging problem in grinding. The machiningefficiency and processing quality can not be considered at the same time. This hasthus limited the widespread applications of advanced engineering ceramics. Thisthesis project thus aimed at developing a high speed grinding technology forefficiency machining of cement carbides and investigating the associated removalmechanisms. Up to now, only a few research has been reported to investigatemechanisms for grinding of cemented carbides in high speed regime with vitrifieddiamond wheels. Therefore, the grinding mechanisms are explored in this thesis forhigh speed grinding of cemented carbides with vitrified diamond wheels at thegrinding speed of up to120m/s. The main work of this thesis can be summarized asfollows:
1. Five kinds of cemented carbides with unique features in their microstructuresand mechanical properties are grinding in high speed regime with vitrified diamondwheel. The horizontal and vertical grinding forces are measured in different grindingparameters (e.g. peripheral wheel speed, depth of cut and workpiece velocity) duringgrinding. Effects of the various grinding parameters, the maximum undeformed chipthickness, the cutting length and physical-mechanical properties of materials on thespecific grinding forces, grinding force ratio, the average grinding force per grain andspecific grinding energy were investigated. The specific grinding forces and thespecific energy not only relate to the maximum undeformed chip thickness and thecutting length but also to physical-mechanical properties of materials and removal modes. The regression model on specific grinding forces and specific energy areestablished according to the relationship of the specific grinding forces and thespecific energy with the maximum undeformed chip thickness and the cutting length,which uses least square method fitting experimental data of high speed grinding.Through the analysis of the distribution mechanism of the grinding energy shows thatthe grinding energy expended is mainly associated with sliding and ductile plowing.A nearly proportional relationship is obtained between the consumed power per unitwidth (Pm) and the plowed face areas generated by all cutting points per unit width(Sw). Compared to conventional grinding, it is found that high speed grinding canobviously reduce grinding forces and the average grinding forces per grain butincrease force ratio and specific grinding energy.
2. During the experiments, temperature distributions along the workpiece surfaceare measured with a foil thermocouple and the energy partition to the workpiece wasestimated using a temperature matching method. The influences of the grindingconditions, including wheel speed, depth of cut, workpiece velocity, and differentkinds of cemented carbides, on the temperatures and energy partitions wereinvestigated. The heat source acting on the workpiece surface is assumed to have aparabolic heat flux distribution is used to simulate the temperature field, for the heatflux density between the grinding wheel and the workpiece is related to the maximumundeformed chip thickness. The study then carries out three-dimensional finiteelement simulation to investigate the transient temperature field induced by thethermal loading to the workpiece. The simulation demonstrates that more convincingresults are obtained using the parabolic heat-flux distribution than the triangularheat-flux distribution. The simulation results is analyzed and compared to the testresults, the simulated result was verified. According to the simulation results oftemperature distribution, we can predict the heat affected grade of the workpiece. Inall cases, the maximum temperature rise at the grinding zone in wet grinding is lessthan185℃when down grinding five kinds of cemented carbides.Under all grindingparameters applied, the energy partitions to the workpiece in wet grinding, obtainedby the temperature matching method varied approximately from2.4to14%.Compared to conventional grinding, it is found that high speed grinding can reduceenergy partition but increase grinding temperature.
3. Grinding vibration acceleration signals are measured under different grinding parameters during grinding. The surface roughness values are measured and themorphological features of ground workpiece surfaces are examined. Thecharacteristics of grinding vibration and surface morphology are researched. Amethod which is the combination of trispectrum and the autoregressive model used toevaluate the relationship between the vibration and the surface roughness.Mechanisms for high speed grinding of cemented carbides with vitrified diamondwheel are elucidated. High speed grinding induces an increase in the vibrationamplitude remarkably and cracks are generated on the ground surface, which havebad influences on the ground surface quality. It is found that grinding conditions, theremoval mode, microstructures and mechanical properties of the cemented carbideshave a significant influence on the ground surfaces. Surface roughness decrease withthe increasing of the peripheral wheel speed, while increase with a larger depth of cutor a faster workpiece velocity or a bigger tungsten carbide particles. The results offitting experimental data of surface roughness using least square method show thatthe workpiece velocity more influence on surface roughness compared to depth of cutand peripheral wheel speed. Surface roughness increases linearly with the maximumundeformed chip thickness. Through contrasting the surface roughness of five kindsof cemented carbides materials after grinding, pointed out that high speed grinding ismore advantageous to brittle material to reduce the surface roughness value. Theobservations on the ground morphology of cemented carbides demonstrate that theground surfaces are generated by the combined removal modes of brittle and ductile.Microscopic examination of the ground surfaces by a digital and video microscopesystem also revealed that material removal occurred mainly by ductile flow whilegrinding the cemented tungsten carbide and by brittle fracture while grinding thecemented titanium-tungsten carbide.
1．本文采用陶瓷结合剂金刚石砂轮分别对五种显微结构和物理性能上具有独特特征的硬质合金进行大量的高速磨削实验。测量了不同加工参数下（砂轮线速度、磨削深度和工件速度）的磨削力。分析了加工参数、单颗磨粒最大未变形切屑厚度、切削长度和材料的物理机械性能对单位宽度磨削力、力比、单颗磨粒承受的磨削力、磨削比能大小的影响。研究发现磨削力和磨削比能与单颗磨粒最大未变形切屑厚度、切削长度、材料的物理机械性能和材料去除方式有关。利用最小二乘法拟合高速磨削实验数据，建立了磨削力和磨削比能与单颗磨粒最大未变形切屑厚度、切削长度的回归关系模型。通过分析磨削比能的分配机理表明，磨削过程中，大部分磨削能量消耗于金刚石磨粒对硬质合金的滑擦与塑性耕犁，单位宽度磨削功率Pm与单位时间单位宽度内金刚石颗粒耕犁面积Sw有很好的线性关系。与低速度磨削相比，高速磨削的磨削力和单颗磨粒承受的磨削力明显减小，而磨削力比和磨削比能增大。
2．通过夹丝热电偶测量不同加工参数下磨削温度，使用温度拟合的方法估算热量分配比例。综合研究了不同加工参数及不同硬质合金类型对磨削弧区的温度特征以及传入工件的热量分配比例特征的影响。由于砂轮与工件接触区的热流密度与未变形切屑厚度有关，因此假设接触弧区中流入工件的热源分布为抛物线分布。用有限元的方法对温度场进行三维仿真，研究工件的热负荷引起的瞬态温度场。仿真表明，用抛物线热流分布比三角形热流分布更有说服力。仿真结果与实验结果进行了对比，验证了仿真结果的合理性。根据仿真获得的温度分布情况，可以预测工件的热影响程度。在湿磨条件下，顺磨五种硬质合金弧区温度低于185℃。热量分配比例随切深、砂轮线速度的增加和工件进给速度的减少而下降。通过温度拟合方法获得的热量分配比例在2.4%-14%范围之间。与低速度磨削相比，高速磨削的磨削温度升高，而热量分配比例下降。
3．测量了不同加工参数下振动加速度信号以及磨削后工件的表面粗糙度和观察磨削后的表面形貌。研究了磨削振动特性和工件表面形貌特征，并用自回归三谱切片评估磨削表面特征的方法表征振动与表面粗糙度之间的关系。探讨了陶瓷结合剂金刚石砂轮高速磨削硬质合金的磨削机理。高速磨削时，振动加速度的幅值明显增大，并会导致磨削表面产生裂纹，影响磨削表面质量。磨削表面质量与加工条件、材料的去除方式、材料的显微结构和物理特性有关。表面粗糙度随磨削深度、工件进给速度、碳化钨颗粒度的增加而增大，随砂轮线速度增加而减小。通过最小二乘法拟合表面粗糙度数据，发现磨削三要素中，工件进给速度对表面粗糙度影响最大。表面粗糙度值随单颗磨粒最大未变形切屑厚度增加而单调递增。对比五种硬质合金材料磨削后的表面粗糙度表明，高速磨削更有利于脆性大的材料降低表面粗糙度值。硬质合金磨削表面形貌的观察表明，磨削加工过程中工件材料以脆性断裂和塑性去除两种方式去除。钨钴类硬质合金主要以塑性方式去除材料，钨钛钴类硬质合金（YT30）主要以脆性断裂的方式去除。
Cemented carbide is a kind of hard and brittle composite material which is a hybridof hard carbide and soft metal phase, and different from soft metal materials and hardand brittle ceramic material. The combination of hard particles in a relative ductilematrix leads to different materials micro-structure. It leads to different grindingperformance. Due to their excellent mechanical properties, such as high strength, highhardness and high wear resistance, cement carbide materials have been widely used inthe engineering fields where high wear resistance and thermal stability are required.Although the preeminent mechanical properties of cement carbides facilitate theirwide applications, they also render a challenging problem in grinding. The machiningefficiency and processing quality can not be considered at the same time. This hasthus limited the widespread applications of advanced engineering ceramics. Thisthesis project thus aimed at developing a high speed grinding technology forefficiency machining of cement carbides and investigating the associated removalmechanisms. Up to now, only a few research has been reported to investigatemechanisms for grinding of cemented carbides in high speed regime with vitrifieddiamond wheels. Therefore, the grinding mechanisms are explored in this thesis forhigh speed grinding of cemented carbides with vitrified diamond wheels at thegrinding speed of up to120m/s. The main work of this thesis can be summarized asfollows:
1. Five kinds of cemented carbides with unique features in their microstructuresand mechanical properties are grinding in high speed regime with vitrified diamondwheel. The horizontal and vertical grinding forces are measured in different grindingparameters (e.g. peripheral wheel speed, depth of cut and workpiece velocity) duringgrinding. Effects of the various grinding parameters, the maximum undeformed chipthickness, the cutting length and physical-mechanical properties of materials on thespecific grinding forces, grinding force ratio, the average grinding force per grain andspecific grinding energy were investigated. The specific grinding forces and thespecific energy not only relate to the maximum undeformed chip thickness and thecutting length but also to physical-mechanical properties of materials and removal modes. The regression model on specific grinding forces and specific energy areestablished according to the relationship of the specific grinding forces and thespecific energy with the maximum undeformed chip thickness and the cutting length,which uses least square method fitting experimental data of high speed grinding.Through the analysis of the distribution mechanism of the grinding energy shows thatthe grinding energy expended is mainly associated with sliding and ductile plowing.A nearly proportional relationship is obtained between the consumed power per unitwidth (Pm) and the plowed face areas generated by all cutting points per unit width(Sw). Compared to conventional grinding, it is found that high speed grinding canobviously reduce grinding forces and the average grinding forces per grain butincrease force ratio and specific grinding energy.
2. During the experiments, temperature distributions along the workpiece surfaceare measured with a foil thermocouple and the energy partition to the workpiece wasestimated using a temperature matching method. The influences of the grindingconditions, including wheel speed, depth of cut, workpiece velocity, and differentkinds of cemented carbides, on the temperatures and energy partitions wereinvestigated. The heat source acting on the workpiece surface is assumed to have aparabolic heat flux distribution is used to simulate the temperature field, for the heatflux density between the grinding wheel and the workpiece is related to the maximumundeformed chip thickness. The study then carries out three-dimensional finiteelement simulation to investigate the transient temperature field induced by thethermal loading to the workpiece. The simulation demonstrates that more convincingresults are obtained using the parabolic heat-flux distribution than the triangularheat-flux distribution. The simulation results is analyzed and compared to the testresults, the simulated result was verified. According to the simulation results oftemperature distribution, we can predict the heat affected grade of the workpiece. Inall cases, the maximum temperature rise at the grinding zone in wet grinding is lessthan185℃when down grinding five kinds of cemented carbides.Under all grindingparameters applied, the energy partitions to the workpiece in wet grinding, obtainedby the temperature matching method varied approximately from2.4to14%.Compared to conventional grinding, it is found that high speed grinding can reduceenergy partition but increase grinding temperature.
3. Grinding vibration acceleration signals are measured under different grinding parameters during grinding. The surface roughness values are measured and themorphological features of ground workpiece surfaces are examined. Thecharacteristics of grinding vibration and surface morphology are researched. Amethod which is the combination of trispectrum and the autoregressive model used toevaluate the relationship between the vibration and the surface roughness.Mechanisms for high speed grinding of cemented carbides with vitrified diamondwheel are elucidated. High speed grinding induces an increase in the vibrationamplitude remarkably and cracks are generated on the ground surface, which havebad influences on the ground surface quality. It is found that grinding conditions, theremoval mode, microstructures and mechanical properties of the cemented carbideshave a significant influence on the ground surfaces. Surface roughness decrease withthe increasing of the peripheral wheel speed, while increase with a larger depth of cutor a faster workpiece velocity or a bigger tungsten carbide particles. The results offitting experimental data of surface roughness using least square method show thatthe workpiece velocity more influence on surface roughness compared to depth of cutand peripheral wheel speed. Surface roughness increases linearly with the maximumundeformed chip thickness. Through contrasting the surface roughness of five kindsof cemented carbides materials after grinding, pointed out that high speed grinding ismore advantageous to brittle material to reduce the surface roughness value. Theobservations on the ground morphology of cemented carbides demonstrate that theground surfaces are generated by the combined removal modes of brittle and ductile.Microscopic examination of the ground surfaces by a digital and video microscopesystem also revealed that material removal occurred mainly by ductile flow whilegrinding the cemented tungsten carbide and by brittle fracture while grinding thecemented titanium-tungsten carbide.
引文
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