涂层刀具切削温度及其测试技术研究
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摘要
涂层刀具是切削加工中应用最广泛的刀具种类之一,统计表明,80%的切削加工应用了涂层刀具。涂层刀具的涂层材料和刀具基体对切削热的产生和温度场分布具有重要影响,切削温度是选择刀具基体和涂层的重要依据。切削热对刀具磨损、刀具寿命、刀具涂层与基体之间的结合强度、刀具与切屑之间的摩擦系数以及刀具与工件已加工表面之间的摩擦系数等均有较大影响。对于刀具切削温度的研究方法有:数学解析法、试验法、数值法、混合法(试验和仿真、解析方法等综合运用)、热源法等。由于涂层刀具切削温度热传导偏微分方程的解析解比较复杂,甚至很难求出。对涂层刀具切削温度的研究主要采用试验和仿真的方法。
本文主要研究涂层刀具热传导性能,揭示涂层材料物理参数、涂层厚度和涂层结构对切削温度的影响规律,找出具有热障作用的刀具涂层材料所具有的特性,研制基于涂层刀具切削温度测试系统。
首先,研究导热系数随温度变化和导热系数为恒定值时涂层刀具稳态热传导刀具的切削温度,分析导热系数对切削温度的影响。建立热传导偏微分方程,采用数值分析方法,计算涂层材料的导热系数取不同恒定值时的切削温度和变导热系数的切削温度。结果表明:在精确计算稳态切削温度时,应采用变热物参数;当用常值来代替变热物性参数时,选择刀具基体材料平均温度时的导热系数,选择涂层材料平均温度或最高温度时的导热系数时,计算误差比较小。研究涂层刀具的热流量。提出将切屑带走的热量和传入刀具的热量都传入刀具,再将切屑带走的热量看作对流换热形式把热量从刀具上散发出去的方法,来分析传入刀具的热流密度和刀-屑接触面温度。结果表明:运用这种方法不仅可以分析传入刀具的热流密度和刀-屑接触面温度,并且还可以优化切削参数。
其次,开发基于涂层刀具切削温度测试系统。研制利用涂层刀具本身作为切削温度传感器的涂层刀具切削温度测试方法,设计制作专用标定装置并对涂层刀具切削温度自测传感器进行标定,分析涂层刀具切削温度自测传感器测温原理。试验结果表明:研制出的涂层刀具温度自测传感器可以对切削温度进行实时测量。
然后,研究涂层刀具切削温度的影响因素及其变化规律,揭示涂层和基体材料以及涂层厚度对涂层刀具切削温度分布的影响规律,为涂层材料和刀具基体材料的合理选择提供理论依据。建立单涂层刀具热传导物理模型和其偏微分方程,用数学解析的方法得到单涂层刀具体内部瞬态切削温度分布和稳态切削温度分布公式,分析影响涂层刀具内部温度分布因素。利用试验得到涂层分别为TiAlN、TiCN/Al_2O_3、TiCN/Al_2O_3/TiN的涂层刀具(分别用K1、K2、K3表示)切削45钢时的刀具前刀面的温度,验证解析推导的单涂层刀具切削温度计算公式。结果表明:涂层材料的热物理性能以及涂层的厚度对刀具的温升有重要影响;涂层材料的导热系数越小、涂层厚度越大则涂层刀具基体内部的稳态切削温度越低;发现涂层的导温系数越小、涂层厚度越大,则刀具瞬态温度越低;导温系数小且导热系数小的刀具涂层具有热障作用;刀具温度试验数值与理论计算值一致。
最后,研究刀具涂层和刀具基体之间的元素扩散,在涂层刀具的热传导分析中提出涂层刀具扩散层理论。采用能谱分析的方法观测涂层刀具涂层、基体之间元素的扩散情况,确定扩散层的厚度,建立涂层刀具扩散层模型,并对其导热系数进行推导。对涂层刀具的切削温度用DEFORM 3D有限元软件进行仿真。结果表明:考虑刀具扩散层仿真得到的涂层刀具的切削温度更接近于试验测量温度。
通过对涂层刀具热传导性能进行研究、分析在不同边界条件下影响涂层刀具切削温度的因素。建立涂层刀具热传导模型和理论,解决目前采用试切法确定涂层材料和厚度的非理论指导做法选用涂层刀具的问题;揭示涂层对涂层刀具热传导的影响规律;从热传导角度提出有效降低涂层刀具切削温度,提高刀具寿命的涂层材料的特性,为发现和应用新的涂层提供理论指导。在应用上,从热传导的角度,对评价不同涂层刀具的性能提供理论依据,为切削加工涂层刀具的选择和涂层刀具的制作奠定基础。开发基于涂层刀具切削温度测试系统,为能够实时、准确地测量涂层刀具切削温度提供仪器和方法。研究导热系数随温度变化和导热系数为恒定值时的涂层刀具稳态热传导时刀具的切削温度,确定用恒定刀具热物性参数来代替变物性参数的选择原则。提出涂层刀具扩散层理论,研究表明考虑扩散层的有限元分析方法,可实现涂层刀具切削温度的高精度仿真。
Coated cutting tools play an important role in manufacturing industries. It is reported that more than 80% cutting tools currently used are coated cutting tools. The coatings of the cutting tool have great influence on cutting heat generation and heat conduction in the tool during machining. The coatings of coated cutting tools affect accuracy of the machined surface and strongly influence tool wear, tool life and frictional behavior in cutting process. The methods to determine temperature in cutting process include analytical method, experimental measurement, numerical analysis, hybrid technique and heat source method. Because the partial different equations of heat conduction are hard to resolve, the method mainly used to obtain the coated tools temperature is numerical analysis method and experimental measurement at present. Past studies have investigated temperatures of coated cutting tools, however, the influence of coating material and coating thickness on temperature distribution in coated tools has not been gotten agreement by now. It has not been built a temperature measurement system to monitor coated tools cutting temperature in real time during machining.
An aim of this research is to find the appropriate proprieties of coating material and coating thickness in heat conduction respect and build a measuring system for cutting coated tools temperature.
To discover how to choose thermal properties of coated cutting tools when calculating cutting temperature, the temperature distributions were obtained with temperature-dependent properties and temperature-independent properties of coated tools using numerical method. The results indicated that temperature-dependent properties should be considered when calculating cutting temperature. To simplify calculation, selecting the thermal conductivities at average temperature to substitute for temperature-dependent properties can reduce calculating error. The method to determine the heat flux into coated tools was proposed based on heat transfer principle. The heat brought away by chip was taken as being transferred to the coated tool firstly, then, carried away by chip from the coated tool with a particular transfer coefficient. The results of the calculated examples indicated that the heat flux and the tool-chip contact temperature can be developed and the optimal cutting parameters can be obtained using this new method.
The present investigation has been conducted in order to develop a new sensor to measure temperatures, especially for cutting presses with coated cutting tools. For this purpose, a novel thermocouple sensor using a tool coating and its substrate has been first fabricated. In order to calibrate the novel sensor accurately, a special instrument was been designed. The working principle of the developed sensor was analyzed. The experimental results showed that this novel technology for measuring cutting temperature is valid in manufacturing processes with coated cutting tools.
In order to find the principle of the influence which coating impact on cutting temperature, several mathematical models of heat conduction in monolayer coated tools has been proposed. The temperature distribution formulations in monolayer coated tools were obtained using analytical method. The influence of different parameters including thermophysical properties of tool coating and tool substrate and thickness of the coating layer on temperature distribution in monolayer coated tools were discussed and illustrated. The experiments were conducted using three different cutting tools with coating layers: TiAlN, TiCN/Al_2O_3, TiCN/Al_2O_3/TiN coated flat-faced inserts of cemented carbide substrate. The work materials used in this study were AISI 1045 carbon steel. The tool-chip contract temperature ware measured. Using the above studied method about thermal properties of coated tools and heat flux into coated tools, the temperature distribution formulations in monolayer coated tools which were deduced analytically previous in this section were validated. Results indicated that low thermal diffusivity coefficient and high thickness of the coating make low transient temperature, and low thermal conductivity coefficient, and high thickness make low steady state temperature in the coated cutting tool, and the calculated temperatures are identical with the measured ones.
A novel approach to prediction of cutting temperatures within coated tools is presented lastly in this paper. The diffusion layer which results thermal resistance between coating and its substrate is considered. A diffusion layer model was firstly developed. Equations for effective thermal conductivity of diffusion layer were then derived. The influences of diffusion layer on cutting temperatures of coated tools were analyzed using finite element method. Results indicated that the simulated temperature with the new model is more accurate than that of the conventional one compared with measured temperature.
In this study the influence of the coatings on coated tools were analyzed. Several models of heat condition in coated tools have been constructed. It is discovered the principle of the coating material and coating thickness affects heat conduction in coated cutting tools. The conclusions of this research developed in this work provide a methodology for design and choice of coated tools in manufacturing industries. A novel sensor using tool-coating and its substrate as thermocouple was firstly fabricated. The coating-substrate thermocouple provides a method to measure cutting temperature of coated tools in real time during machining. The cutting temperatures of coated tools with temperature-dependent and constant thermal properties were investigated. This work provides a methodology of how to choose the thermal parameter of coatings when calculating cutting coated tool temperature. The diffusion layer theory about coated tools was firstly developed. The model considering diffusion layer of coated tools in more reasonable than the conventional one.
This dissertation is supported by National Great Project of Scientific and Technical Supporting Programs of China During the 11th Five-year Plan (NO. 2008BAF32B01) and National Basic Research Program of China (No.2009CB724401).
本文主要研究涂层刀具热传导性能,揭示涂层材料物理参数、涂层厚度和涂层结构对切削温度的影响规律,找出具有热障作用的刀具涂层材料所具有的特性,研制基于涂层刀具切削温度测试系统。
首先,研究导热系数随温度变化和导热系数为恒定值时涂层刀具稳态热传导刀具的切削温度,分析导热系数对切削温度的影响。建立热传导偏微分方程,采用数值分析方法,计算涂层材料的导热系数取不同恒定值时的切削温度和变导热系数的切削温度。结果表明:在精确计算稳态切削温度时,应采用变热物参数;当用常值来代替变热物性参数时,选择刀具基体材料平均温度时的导热系数,选择涂层材料平均温度或最高温度时的导热系数时,计算误差比较小。研究涂层刀具的热流量。提出将切屑带走的热量和传入刀具的热量都传入刀具,再将切屑带走的热量看作对流换热形式把热量从刀具上散发出去的方法,来分析传入刀具的热流密度和刀-屑接触面温度。结果表明:运用这种方法不仅可以分析传入刀具的热流密度和刀-屑接触面温度,并且还可以优化切削参数。
其次,开发基于涂层刀具切削温度测试系统。研制利用涂层刀具本身作为切削温度传感器的涂层刀具切削温度测试方法,设计制作专用标定装置并对涂层刀具切削温度自测传感器进行标定,分析涂层刀具切削温度自测传感器测温原理。试验结果表明:研制出的涂层刀具温度自测传感器可以对切削温度进行实时测量。
然后,研究涂层刀具切削温度的影响因素及其变化规律,揭示涂层和基体材料以及涂层厚度对涂层刀具切削温度分布的影响规律,为涂层材料和刀具基体材料的合理选择提供理论依据。建立单涂层刀具热传导物理模型和其偏微分方程,用数学解析的方法得到单涂层刀具体内部瞬态切削温度分布和稳态切削温度分布公式,分析影响涂层刀具内部温度分布因素。利用试验得到涂层分别为TiAlN、TiCN/Al_2O_3、TiCN/Al_2O_3/TiN的涂层刀具(分别用K1、K2、K3表示)切削45钢时的刀具前刀面的温度,验证解析推导的单涂层刀具切削温度计算公式。结果表明:涂层材料的热物理性能以及涂层的厚度对刀具的温升有重要影响;涂层材料的导热系数越小、涂层厚度越大则涂层刀具基体内部的稳态切削温度越低;发现涂层的导温系数越小、涂层厚度越大,则刀具瞬态温度越低;导温系数小且导热系数小的刀具涂层具有热障作用;刀具温度试验数值与理论计算值一致。
最后,研究刀具涂层和刀具基体之间的元素扩散,在涂层刀具的热传导分析中提出涂层刀具扩散层理论。采用能谱分析的方法观测涂层刀具涂层、基体之间元素的扩散情况,确定扩散层的厚度,建立涂层刀具扩散层模型,并对其导热系数进行推导。对涂层刀具的切削温度用DEFORM 3D有限元软件进行仿真。结果表明:考虑刀具扩散层仿真得到的涂层刀具的切削温度更接近于试验测量温度。
通过对涂层刀具热传导性能进行研究、分析在不同边界条件下影响涂层刀具切削温度的因素。建立涂层刀具热传导模型和理论,解决目前采用试切法确定涂层材料和厚度的非理论指导做法选用涂层刀具的问题;揭示涂层对涂层刀具热传导的影响规律;从热传导角度提出有效降低涂层刀具切削温度,提高刀具寿命的涂层材料的特性,为发现和应用新的涂层提供理论指导。在应用上,从热传导的角度,对评价不同涂层刀具的性能提供理论依据,为切削加工涂层刀具的选择和涂层刀具的制作奠定基础。开发基于涂层刀具切削温度测试系统,为能够实时、准确地测量涂层刀具切削温度提供仪器和方法。研究导热系数随温度变化和导热系数为恒定值时的涂层刀具稳态热传导时刀具的切削温度,确定用恒定刀具热物性参数来代替变物性参数的选择原则。提出涂层刀具扩散层理论,研究表明考虑扩散层的有限元分析方法,可实现涂层刀具切削温度的高精度仿真。
Coated cutting tools play an important role in manufacturing industries. It is reported that more than 80% cutting tools currently used are coated cutting tools. The coatings of the cutting tool have great influence on cutting heat generation and heat conduction in the tool during machining. The coatings of coated cutting tools affect accuracy of the machined surface and strongly influence tool wear, tool life and frictional behavior in cutting process. The methods to determine temperature in cutting process include analytical method, experimental measurement, numerical analysis, hybrid technique and heat source method. Because the partial different equations of heat conduction are hard to resolve, the method mainly used to obtain the coated tools temperature is numerical analysis method and experimental measurement at present. Past studies have investigated temperatures of coated cutting tools, however, the influence of coating material and coating thickness on temperature distribution in coated tools has not been gotten agreement by now. It has not been built a temperature measurement system to monitor coated tools cutting temperature in real time during machining.
An aim of this research is to find the appropriate proprieties of coating material and coating thickness in heat conduction respect and build a measuring system for cutting coated tools temperature.
To discover how to choose thermal properties of coated cutting tools when calculating cutting temperature, the temperature distributions were obtained with temperature-dependent properties and temperature-independent properties of coated tools using numerical method. The results indicated that temperature-dependent properties should be considered when calculating cutting temperature. To simplify calculation, selecting the thermal conductivities at average temperature to substitute for temperature-dependent properties can reduce calculating error. The method to determine the heat flux into coated tools was proposed based on heat transfer principle. The heat brought away by chip was taken as being transferred to the coated tool firstly, then, carried away by chip from the coated tool with a particular transfer coefficient. The results of the calculated examples indicated that the heat flux and the tool-chip contact temperature can be developed and the optimal cutting parameters can be obtained using this new method.
The present investigation has been conducted in order to develop a new sensor to measure temperatures, especially for cutting presses with coated cutting tools. For this purpose, a novel thermocouple sensor using a tool coating and its substrate has been first fabricated. In order to calibrate the novel sensor accurately, a special instrument was been designed. The working principle of the developed sensor was analyzed. The experimental results showed that this novel technology for measuring cutting temperature is valid in manufacturing processes with coated cutting tools.
In order to find the principle of the influence which coating impact on cutting temperature, several mathematical models of heat conduction in monolayer coated tools has been proposed. The temperature distribution formulations in monolayer coated tools were obtained using analytical method. The influence of different parameters including thermophysical properties of tool coating and tool substrate and thickness of the coating layer on temperature distribution in monolayer coated tools were discussed and illustrated. The experiments were conducted using three different cutting tools with coating layers: TiAlN, TiCN/Al_2O_3, TiCN/Al_2O_3/TiN coated flat-faced inserts of cemented carbide substrate. The work materials used in this study were AISI 1045 carbon steel. The tool-chip contract temperature ware measured. Using the above studied method about thermal properties of coated tools and heat flux into coated tools, the temperature distribution formulations in monolayer coated tools which were deduced analytically previous in this section were validated. Results indicated that low thermal diffusivity coefficient and high thickness of the coating make low transient temperature, and low thermal conductivity coefficient, and high thickness make low steady state temperature in the coated cutting tool, and the calculated temperatures are identical with the measured ones.
A novel approach to prediction of cutting temperatures within coated tools is presented lastly in this paper. The diffusion layer which results thermal resistance between coating and its substrate is considered. A diffusion layer model was firstly developed. Equations for effective thermal conductivity of diffusion layer were then derived. The influences of diffusion layer on cutting temperatures of coated tools were analyzed using finite element method. Results indicated that the simulated temperature with the new model is more accurate than that of the conventional one compared with measured temperature.
In this study the influence of the coatings on coated tools were analyzed. Several models of heat condition in coated tools have been constructed. It is discovered the principle of the coating material and coating thickness affects heat conduction in coated cutting tools. The conclusions of this research developed in this work provide a methodology for design and choice of coated tools in manufacturing industries. A novel sensor using tool-coating and its substrate as thermocouple was firstly fabricated. The coating-substrate thermocouple provides a method to measure cutting temperature of coated tools in real time during machining. The cutting temperatures of coated tools with temperature-dependent and constant thermal properties were investigated. This work provides a methodology of how to choose the thermal parameter of coatings when calculating cutting coated tool temperature. The diffusion layer theory about coated tools was firstly developed. The model considering diffusion layer of coated tools in more reasonable than the conventional one.
This dissertation is supported by National Great Project of Scientific and Technical Supporting Programs of China During the 11th Five-year Plan (NO. 2008BAF32B01) and National Basic Research Program of China (No.2009CB724401).
引文
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