基于预应力切削的加工表面残余应力控制研究
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摘要
随着现代制造技术的发展，大飞机、高铁、核设施等大型设备相继出现。这些设备有高速重载长时间运行的特点，零部件工作环境恶劣复杂，但又往往对安全有着极端的要求，这对关键部件，如轴承、曲轴、传动轴的疲劳寿命和可靠性的要求愈来愈高，他们的疲劳寿命预测和分析成为学术界研究重点。研究的结果表明工件的疲劳寿命和加工表面的残余应力状态有重要的关系，残余压应力能抑制工件疲劳破坏，延长疲劳寿命，残余拉应力则相反，会加速疲劳破坏的出现。因此对工件已加工表面的残余应力的了解和控制，使零件已加工表面呈现稳定而较大的压应力状态，就成了加工出高质量和高可靠性零件的关键。但目前对残余应力的产生集中在定性范围，没有对残余应力定量控制进行系统研究，对加工过程中获得残余压应力缺乏现实方法。本文通过热力耦合理论分析、切削实验和有限元模拟与试验研究相结合的方法，对加工表面残余应力的分布以及控制残余应力的相关工艺进行了研究，对提高金属零件的疲劳强度有着重要的意义。
全文总结了残余应力和切削残余应力的国内外研究状况，提出来利用预应力切削方法对加工表面残余应力进行控制，本文主要展开了以下几个方面的的研究内容：（1）在预应力切削原理的基础上,设计了一种用于车削加工的预应力加载装置，以解决对工件施加较大预应力同时进行车削的难题。通过40Cr合金试样的车削实验验证加载装置可行性，同时了解预应力硬态切削在试样加工表面残余压应力和其他加工表面质量的状况，并对预应力导致工件的变形和切削加工中的补偿进行了初步探讨。（2）对预应力切削的已加工表面残余应力状态进行热力耦合分析，对热效应和机械效应怎么影响到加工残余应力的具体分布进行探讨，然后通过大钝圆刀具切削实验和切削液以及液氮切削实验论证了结论的正确性。（3）在建立了预应力切削的有限元模拟模型的基础上，利用预应力切削的有限元软件进行正交模拟，了解预应力和切削参数对残余应力影响的显著性；在此基础上通过一元线性回归分析，推导了一个以预应力和切削参数为变量的加工表面残余应力预测公式；最后通过实验论证有限元模拟和预测公式的可靠性。（4）通过45钢的车削实验，采用数理统计方法对其加工表面残余应力的离散性进行研究。在此基础上进一步提出和讨论了残余应力公差概念，作为技术参数来指导工件的加工和检测，并讨论了该概念的可行性。
Large aircraft, high-speed rail, nuclear facilities and other large equipment have appearedbecause of the development of modern manufacturing technology. These devices have ancharacteristics of long-running, high-speed and great loading, and then their parts maybework in complex environment. These equipment often be ask to have extreme security, theirimportant components, such as bearings, crankshaft, transmission shaft, must have longerfatigue life and greater working reliability, so that fatigue life prediction andenhance become an academic research focus. Research results show that the fatigue life hasan important relationship with machined residual stress state, residual compressive stress caninhibit the fatigue failure and obtain longer fatigue life; residual tensile stress has a contraryeffect and lead a shorter fatigue life. It is easy to know that understanding andcontrol of the residual stress is a key to obtain high quality and reliability parts. However,researches of residual stress have qualitative results, it is lack that the study on thequantitative control of residual stress, and lack of realistic methods for control of residualcompressive stress. A comprehensive study is carried out on the control of residual stress onmachined surface by thermal coupling theory analysis, finite element simulation andcutting experiments. The work in this dissertation can provide a new way to improve thefatigue strength of these parts, which is instructive to the application and popularization ofresidual stress control technology.
Affect on control of residual stress by pre-stress cutting method is researched in the paper.Six chapters are included in this dissertation, and the main work of is as follows:(1)Thispaper presents a new loading device that can offer a larger pre-stress on part during pre-stressturning so as to solving the problem of pre-stress loading. Screw shaft turning experimentwith PCBN tool is made by loading different magnitude of pre-stress. The variety ofpre-stress, cutting force, tool wear and surface residual stress in different condition ismeasured, as well as the surface roughness of workpiece. Experimental results show thefeasibility of the loading device and indicate that pre-stress hard cutting can improve theresidual stress state on machined surface of screw and get a better surface roughness.(2)The residual stress state of machined surface is studied with thermo-mechanical couplinganalysis. The value and distribution of residual stress are investigated in the overlap ofcompositing mechanical stress and thermal stress in the machined surface, and the generatedconditions of residual stress is qualitatively discussed. Both the cutting edge round andpre-stress affects on residual stress of of machined surface is further discussed, based on above-mentioned, it indicates that the rounded cutting edge can affect both the value anddistribution of residual stress of machined surface; the pre-stress can effectively increasethe residual compressive stress but has no influence on its distribution. The experiments ofpre-stress hard cutting for40Cr alloy steel with different cutting edge round is carried out, itsresults coincided with theoretical analysis, and it proves the reasonableness of the theory.Then turning experiments on AISI1045steel is process by using various cutting fluid andliquid nitrogen condition. Residual stress on machined surface is generated in roughmachining and fine machining with different rounded cutting edge radius. The effects ofcutting fluid and liquid nitrogen on residual stress are obtained by compared with dry cutting.The results show that cutting fluid and liquid nitrogen have influence on residual stress ofmachined surface of AISI1045steel. Liquid nitrogen generates residual compressive stress inall specimens; the cooling and lubricant effect of cutting fluid affects the maximum residualstress and the depth of stress layer; Cutting fluid and liquid nitrogen have various effectdegrees on rough machining and fine machining.(3)Relevant theories of metal cutting arereviewed first. Then, based on the equations in finite element simulation and consideration ofelastic-plastic deformation in the process of cutting, several critical techniques in cuttingsimulation are considered. After that, the finite element model of three-dimensionalorthogonal hard cutting is established based on the efforts mentioned before, the cuttingprocess is simulated in orthogonal experimental arrangement. In the end, comparing thesimulation results and the practical measurements in orthogonal cutting experiments, theproposed model is validated to be effective. The results of the simulation and experimentshow that Pre-stress had obvious significance for residual stress than those significances ofmachining parameters; a prediction formula for residual stress of pre-stress hard turning isobtained from the experiment.(4)An experimental study on the scatter of surface residualstress is induced by rough turning and finishing turning of45steel on the condition of drycutting and coolant cutting using statistical methods. It is showed that the scatter of surfaceresidual stress is inevitable; the same machined surface has scattered residual stress; differentparts, different processing conditions result of different scattered degree of the surfaceresidual stress; rough cutting results of more scattered degree than finishing, dry cuttingprocess results of more scattered surface residual stress than wet cutting. The scatter ofworkpieces is in a limited range. Processing and testing can be guided with the workpieces’residual stress tolerance to ensure the accuracy of residual stress in the workpiece.
全文总结了残余应力和切削残余应力的国内外研究状况，提出来利用预应力切削方法对加工表面残余应力进行控制，本文主要展开了以下几个方面的的研究内容：（1）在预应力切削原理的基础上,设计了一种用于车削加工的预应力加载装置，以解决对工件施加较大预应力同时进行车削的难题。通过40Cr合金试样的车削实验验证加载装置可行性，同时了解预应力硬态切削在试样加工表面残余压应力和其他加工表面质量的状况，并对预应力导致工件的变形和切削加工中的补偿进行了初步探讨。（2）对预应力切削的已加工表面残余应力状态进行热力耦合分析，对热效应和机械效应怎么影响到加工残余应力的具体分布进行探讨，然后通过大钝圆刀具切削实验和切削液以及液氮切削实验论证了结论的正确性。（3）在建立了预应力切削的有限元模拟模型的基础上，利用预应力切削的有限元软件进行正交模拟，了解预应力和切削参数对残余应力影响的显著性；在此基础上通过一元线性回归分析，推导了一个以预应力和切削参数为变量的加工表面残余应力预测公式；最后通过实验论证有限元模拟和预测公式的可靠性。（4）通过45钢的车削实验，采用数理统计方法对其加工表面残余应力的离散性进行研究。在此基础上进一步提出和讨论了残余应力公差概念，作为技术参数来指导工件的加工和检测，并讨论了该概念的可行性。
Large aircraft, high-speed rail, nuclear facilities and other large equipment have appearedbecause of the development of modern manufacturing technology. These devices have ancharacteristics of long-running, high-speed and great loading, and then their parts maybework in complex environment. These equipment often be ask to have extreme security, theirimportant components, such as bearings, crankshaft, transmission shaft, must have longerfatigue life and greater working reliability, so that fatigue life prediction andenhance become an academic research focus. Research results show that the fatigue life hasan important relationship with machined residual stress state, residual compressive stress caninhibit the fatigue failure and obtain longer fatigue life; residual tensile stress has a contraryeffect and lead a shorter fatigue life. It is easy to know that understanding andcontrol of the residual stress is a key to obtain high quality and reliability parts. However,researches of residual stress have qualitative results, it is lack that the study on thequantitative control of residual stress, and lack of realistic methods for control of residualcompressive stress. A comprehensive study is carried out on the control of residual stress onmachined surface by thermal coupling theory analysis, finite element simulation andcutting experiments. The work in this dissertation can provide a new way to improve thefatigue strength of these parts, which is instructive to the application and popularization ofresidual stress control technology.
Affect on control of residual stress by pre-stress cutting method is researched in the paper.Six chapters are included in this dissertation, and the main work of is as follows:(1)Thispaper presents a new loading device that can offer a larger pre-stress on part during pre-stressturning so as to solving the problem of pre-stress loading. Screw shaft turning experimentwith PCBN tool is made by loading different magnitude of pre-stress. The variety ofpre-stress, cutting force, tool wear and surface residual stress in different condition ismeasured, as well as the surface roughness of workpiece. Experimental results show thefeasibility of the loading device and indicate that pre-stress hard cutting can improve theresidual stress state on machined surface of screw and get a better surface roughness.(2)The residual stress state of machined surface is studied with thermo-mechanical couplinganalysis. The value and distribution of residual stress are investigated in the overlap ofcompositing mechanical stress and thermal stress in the machined surface, and the generatedconditions of residual stress is qualitatively discussed. Both the cutting edge round andpre-stress affects on residual stress of of machined surface is further discussed, based on above-mentioned, it indicates that the rounded cutting edge can affect both the value anddistribution of residual stress of machined surface; the pre-stress can effectively increasethe residual compressive stress but has no influence on its distribution. The experiments ofpre-stress hard cutting for40Cr alloy steel with different cutting edge round is carried out, itsresults coincided with theoretical analysis, and it proves the reasonableness of the theory.Then turning experiments on AISI1045steel is process by using various cutting fluid andliquid nitrogen condition. Residual stress on machined surface is generated in roughmachining and fine machining with different rounded cutting edge radius. The effects ofcutting fluid and liquid nitrogen on residual stress are obtained by compared with dry cutting.The results show that cutting fluid and liquid nitrogen have influence on residual stress ofmachined surface of AISI1045steel. Liquid nitrogen generates residual compressive stress inall specimens; the cooling and lubricant effect of cutting fluid affects the maximum residualstress and the depth of stress layer; Cutting fluid and liquid nitrogen have various effectdegrees on rough machining and fine machining.(3)Relevant theories of metal cutting arereviewed first. Then, based on the equations in finite element simulation and consideration ofelastic-plastic deformation in the process of cutting, several critical techniques in cuttingsimulation are considered. After that, the finite element model of three-dimensionalorthogonal hard cutting is established based on the efforts mentioned before, the cuttingprocess is simulated in orthogonal experimental arrangement. In the end, comparing thesimulation results and the practical measurements in orthogonal cutting experiments, theproposed model is validated to be effective. The results of the simulation and experimentshow that Pre-stress had obvious significance for residual stress than those significances ofmachining parameters; a prediction formula for residual stress of pre-stress hard turning isobtained from the experiment.(4)An experimental study on the scatter of surface residualstress is induced by rough turning and finishing turning of45steel on the condition of drycutting and coolant cutting using statistical methods. It is showed that the scatter of surfaceresidual stress is inevitable; the same machined surface has scattered residual stress; differentparts, different processing conditions result of different scattered degree of the surfaceresidual stress; rough cutting results of more scattered degree than finishing, dry cuttingprocess results of more scattered surface residual stress than wet cutting. The scatter ofworkpieces is in a limited range. Processing and testing can be guided with the workpieces’residual stress tolerance to ensure the accuracy of residual stress in the workpiece.
引文
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