马氏体不锈钢单磨粒磨削过程的建模研究（英文）
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摘要
单磨粒磨削是宏观尺度磨削的简化模型。相比于传统实验研究,有限元分析是一种强有力的研究工具,可以计算得到单磨粒磨削过程的多物理场分布。本文基于2Cr12Ni4Mo3VNbN不锈钢的动态力学模型和磨粒的数学统计模型,使用AdvantEdge软件对单磨粒的磨削过程进行了有限元建模,计算得到了磨削温度场、应力应变场、磨削力等物理量。搭建了单磨粒磨削试验平台,测量了不同工艺参数下的磨削力变化。通过对比磨削力的实验值和计算值,结果表明有限元模型可以较好地描述单磨粒磨削过程。试验和仿真数据一致表明,法向磨削力和切向磨削力均与磨粒的切速、切深成正比;工件的最大磨削温度位于磨粒前刃面的下方,而应力应变最大值则位于磨粒尖端的下方。单磨粒磨削过程的应变变形率高达10~6 s~(–1),远超其他常规切削方式的应变变形率。
Single grit grinding is the simplified model to abstract the macro scale grinding.Finite element analysis is a strong tool to study the physical fields during a single grit grinding process, compared to experimental research.Based on the dynamic mechanical behavior of 2Cr12Ni4Mo3VNbN steel and the mathematical statistics of abrasive grit, modeling of the single grit grinding process was conducted by using commercial software AdvantE dge.The validation experiment was designed to validate the correctness of the FEA model by contrast with grinding force.The validation result shows that the FEA model can well describe the single grit grinding process.Then the grinding force and multi-physics fields were studied by experimental and simulation results.It was found that both the normal and tangential grinding forces were linearly related to the cutting speed and cutting depth.The maximum temperature is located in the subsurface of the workpiece in front of the grit, while the maximum stress and strain are located under the grit tip.The strain rate can reach as high as about 10~6 s~(–1) during the single grit grinding,which is larger than other traditional machining operations.
Single grit grinding is the simplified model to abstract the macro scale grinding.Finite element analysis is a strong tool to study the physical fields during a single grit grinding process, compared to experimental research.Based on the dynamic mechanical behavior of 2Cr12Ni4Mo3VNbN steel and the mathematical statistics of abrasive grit, modeling of the single grit grinding process was conducted by using commercial software AdvantE dge.The validation experiment was designed to validate the correctness of the FEA model by contrast with grinding force.The validation result shows that the FEA model can well describe the single grit grinding process.Then the grinding force and multi-physics fields were studied by experimental and simulation results.It was found that both the normal and tangential grinding forces were linearly related to the cutting speed and cutting depth.The maximum temperature is located in the subsurface of the workpiece in front of the grit, while the maximum stress and strain are located under the grit tip.The strain rate can reach as high as about 10~6 s~(–1) during the single grit grinding,which is larger than other traditional machining operations.
引文
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[16]YAN Lan.Research on grinding mechanism of hardened cold-work die steel based on single grain cutting[D].Changsha:Hunan University,2010.(in Chinese)
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[19]WANG Xiang-yu,HUANG Chuan-zhen,ZOU Bin,LIUHan-lian,ZHU Hong-tao,WANG Jun.Dynamic behavior and a modified Johnson-Cook constitutive model of Inconel718 at high strain rate and elevated temperature[J].Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing,2013,580:385-390.DOI:https://doi.org/10.1016/j.msea.2013.05.062.
[20]NIE Zheng-guo,WANG Gang,YU Jian-chao,LIU De-hao,RONG Yi-ming.Phase-based constitutive modeling and experimental study for dynamic mechanical behavior in martensitic stainless steel under high strain rates in a thermal cycle[J].Mechanics of Materials,2006,101:160-169.DOI:https://doi.org/10.1016/j.mechmat.2016.08.003.
[2]MALKIN S,GUO C.Thermal analysis of grinding[J].CIRPAnnals-Manufacturing Technology,2007,56(2):760-782.DOI:https://doi.org/10.1016/j.cirp.2007.10.005.
[3]KIM H J,KIM N K,KWAK J S.Heat flux distribution model by sequential algorithm of inverse heat transfer for determining workpiece temperature in creep feed grinding[J].International Journal of Machine Tools and Manufacture,2006,46(15):2086-2093.DOI:https://doi.org/10.1016/j.ijmachtools.2005.12.007.
[4]DOMAN D A,WARKENTIN A,BAUER R.Finite element modeling approaches in grinding[J].International Journal of Machine Tools and Manufacture,2009,49(2):109-116.DOIhttps://doi.org/10.1016/j.ijmachtools.2008.10.002.
[5]GORANA V K,JAIN V K,LAL G K.Forces prediction during material deformation in abrasive flow machining[J].Wear,2006,260(1,2):128-139.DOI:https://doi.org/10.1016/j.wear.2004.12.038.
[6]BARGE M,RECH J,HAMDI H,BERGHEAU J M.Experimental study of abrasive process[J].Wear,2008,264(5,6):382-388.DOI:https://doi.org/10.1016/j.wear.2006.08.046.
[7]OUMLPOUMLZ T T,CHEN X.Single grit grinding simulation by using finite element analysis[J].AIPConference Proceedings,2011,1315(1):1467-1472.DOI:https://doi.org/10.1063/1.3552394.
[8]AURICH J C,KIRSCH B.Kinematic simulation of high-performance grinding for analysis of chip parameters of single grains[J].CIRP Journal of Manufacturing Science and Technology,2012,5(3):164-174.DOI:https://doi.org/10.1016/j.cirpj.2012.07.004.
[9]ZHU D,YAN S,LI B.Single-grit modeling and simulation of crack initiation and propagation in Si C grinding using maximum undeformed chip thickness[J].Computational Materials Science,2014,92:13-21.DOI:https://doi.org/10.1016/j.commatsci.2014.05.019.
[10]NIE Zhen-guo,WANG Gang,LIU De-hao,RONG Yi-ming(Kevin).A statistical model of equivalent grinding heat source based on random distributed grains[J].Journal of Manufacturing Science and Engineering,2017,140(5):051016.DOI:10.1115/1.4038729.
[11]NADOLNY K,KAP?ONEK W.Design of a device for precision shaping of grinding wheel macro-and microgeometry[J].Journal of Central South University,2012,19(1):135-143.DOI:https://doi.org/10.1007/s11771-012-0982-9
[12]?P?Z T T,CHEN X.Experimental investigation of material removal mechanism in single grit grinding[J].International Journal of Machine Tools and Manufacture,2012,63:32-40.DOI:https://doi.org/10.1016/j.ijmachtools.2012.07.010.
[13]WANG H,SUBHASH G,ABHIJIT CHANDRA A.Characteristics of single-grit rotating scratch with a conical tool on pure titanium[J].Wear,2001,249(7):566-581.DOI:https://doi.org/10.1016/S0043-1648(01)00585-3.
[14]BUTLER-SMITH P W,AXINTE D A,DAINE M.Solid diamond micro-grinding tools:From innovative design and fabrication to preliminary performance evaluation in Ti-6Al-4V[J].International Journal of Machine Tools and Manufacture,2012,59:55-64.DOI:https://doi.org/10.1016/j.ijmachtools.2012.03.003.
[15]ANDERSON D,WARKENTIN A,BAUER R.Experimental and numerical investigations of single abrasive-grain cutting[J].International Journal of Machine Tools and Manufacture,2011,51(12):898-910.DOI:https://doi.org/10.1016/j.ijmachtools.2011.08.006.
[16]YAN Lan.Research on grinding mechanism of hardened cold-work die steel based on single grain cutting[D].Changsha:Hunan University,2010.(in Chinese)
[17]JOHNSON G R,COOK W H.A constitutive model and data for metals subjected to large strains,high strain rates and high temperatures[C]//Proceedings of the 7th International Symposium on Ballistics.1983:541-547.Article ID:10030415477.
[18]GAO C Y,ZHANG L C.Constitutive modelling of plasticity of fcc metals under extremely high strain rates[J].International Journal of Plasticity,2012,32:121-133.DOI:https://doi.org/10.1016/j.ijplas.2011.12.001.
[19]WANG Xiang-yu,HUANG Chuan-zhen,ZOU Bin,LIUHan-lian,ZHU Hong-tao,WANG Jun.Dynamic behavior and a modified Johnson-Cook constitutive model of Inconel718 at high strain rate and elevated temperature[J].Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing,2013,580:385-390.DOI:https://doi.org/10.1016/j.msea.2013.05.062.
[20]NIE Zheng-guo,WANG Gang,YU Jian-chao,LIU De-hao,RONG Yi-ming.Phase-based constitutive modeling and experimental study for dynamic mechanical behavior in martensitic stainless steel under high strain rates in a thermal cycle[J].Mechanics of Materials,2006,101:160-169.DOI:https://doi.org/10.1016/j.mechmat.2016.08.003.