蠕墨铸铁铣削机理及其应用研究
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摘要
HX型气缸盖是HX型大功率内燃机车柴油机的核心部件之一,是典型的多面多孔系的箱体类零件,其结构复杂、精度要求高。为适应柴油机高性能的要求,HX型气缸盖选用了蠕墨铸铁材料,是一种典型的难加工材料。在加工工序中,HX型气缸盖的铣削加工是影响加工效率的重要环节。
本文从生产实际需求出发,以提高铣削加工效率为目的,应用山特维克H13A无涂层刀片和GC1020涂层刀片进行铣削加工试验,对蠕墨铸铁材料铣削机理进行了试验研究。对铣削试验的切屑形态、切削力、刀具磨损以及加工表面情况各因素进行综合分析和研究,选用合理刀具与铣削优化参数,结合生产实际应用,从而获得较为合理的、优化的HX气缸盖工艺参数。同时又对蠕墨铸铁铣削机理进行建模仿真研究,进一步为实际应用提供指导。本文的主要研究内容如下:
1.根据蠕墨铸铁切削特点,选用了H13A无涂层刀片和GC1020涂层刀片,采用正交试验设计方法,建立了以切削速度、每齿进给量和切深为因素的三因素四水平的试验方案。
2.通过对试验中的切屑形态、切削力、刀具磨损以及加工表面情况进行评价和分析,并建立切削用量对切削力和表面粗糙度( Ra)的多因数交互的回归模型,深入系统地研究蠕墨铸铁的铣削机理。
3.根据试验数据,采用多目标优化的方法对切削参数进行优化,将其应用到气缸盖加工中,对应用的效果进行评价分析并推广。
4.利用试验数据进行建模仿真研究,从理论上验证蠕墨铸铁铣削机理的试验结论。
The HX type cylinder head is a key part of the diesel engine used in HX type high power diesel locomotive, which is a typical box structure with multiple faces and holes. Its structure is complex and accuracy requirement is high. In order to adapt to the high performance required by the diesel engine, HX type cylinder head chooses Compacted graphite iron is chosen as the HX type cylinder head material which is difficult to machine. Among all the machining processes, the milling operation is a critical and influences the machining efficiency significantly.
This research is based on the current production demand, aiming at promoting the milling efficiency. In the milling test H13A uncoated insert and GC 1020 coated insert from Sandvik was used, and the milling mechanism on the Compacted graphite iron was analysed in terms of chips form, cutting force, tool wear and the finished surface quality. After choosing reasonable inserts and obtaining optimized parameters with the consideration of real production, we can get reasonable and optimized process parameters for HX type cylinder head. Meanwhile, this research carries out the finite element simulation analysis on the Compacted graphite iron milling mechanism to guide the practical application.
1.According to the characteristic of Compacted graphite iron, H13A uncoated insert and GC1020 insert was chosen it this research. Orthogonal experimental design method was applied with three factors—cutting speed, feed rate and cutting depth which all are divided into 4 different levels.
2.The cutting chip form, cutting force, tool wear and surface machining condition were evaluated and analysisd and a multiple-factors interactive and regressive model was built where cutting force and surface roughness(Ra) is a function of cutting parameters to deeply understand the milling mechanism of Compacted graphite iron.
3.According to test data, the cutting parameters was optimized through optimizing multiple targets then the parameters was applied in the cylinder head machining. the application result was evaluated and the parameters was popularized.
4.Modeling simulation research was carried out based on the test data to verify the reliability of the test conclusion on the Compacted graphite iron in theory.
本文从生产实际需求出发,以提高铣削加工效率为目的,应用山特维克H13A无涂层刀片和GC1020涂层刀片进行铣削加工试验,对蠕墨铸铁材料铣削机理进行了试验研究。对铣削试验的切屑形态、切削力、刀具磨损以及加工表面情况各因素进行综合分析和研究,选用合理刀具与铣削优化参数,结合生产实际应用,从而获得较为合理的、优化的HX气缸盖工艺参数。同时又对蠕墨铸铁铣削机理进行建模仿真研究,进一步为实际应用提供指导。本文的主要研究内容如下:
1.根据蠕墨铸铁切削特点,选用了H13A无涂层刀片和GC1020涂层刀片,采用正交试验设计方法,建立了以切削速度、每齿进给量和切深为因素的三因素四水平的试验方案。
2.通过对试验中的切屑形态、切削力、刀具磨损以及加工表面情况进行评价和分析,并建立切削用量对切削力和表面粗糙度( Ra)的多因数交互的回归模型,深入系统地研究蠕墨铸铁的铣削机理。
3.根据试验数据,采用多目标优化的方法对切削参数进行优化,将其应用到气缸盖加工中,对应用的效果进行评价分析并推广。
4.利用试验数据进行建模仿真研究,从理论上验证蠕墨铸铁铣削机理的试验结论。
The HX type cylinder head is a key part of the diesel engine used in HX type high power diesel locomotive, which is a typical box structure with multiple faces and holes. Its structure is complex and accuracy requirement is high. In order to adapt to the high performance required by the diesel engine, HX type cylinder head chooses Compacted graphite iron is chosen as the HX type cylinder head material which is difficult to machine. Among all the machining processes, the milling operation is a critical and influences the machining efficiency significantly.
This research is based on the current production demand, aiming at promoting the milling efficiency. In the milling test H13A uncoated insert and GC 1020 coated insert from Sandvik was used, and the milling mechanism on the Compacted graphite iron was analysed in terms of chips form, cutting force, tool wear and the finished surface quality. After choosing reasonable inserts and obtaining optimized parameters with the consideration of real production, we can get reasonable and optimized process parameters for HX type cylinder head. Meanwhile, this research carries out the finite element simulation analysis on the Compacted graphite iron milling mechanism to guide the practical application.
1.According to the characteristic of Compacted graphite iron, H13A uncoated insert and GC1020 insert was chosen it this research. Orthogonal experimental design method was applied with three factors—cutting speed, feed rate and cutting depth which all are divided into 4 different levels.
2.The cutting chip form, cutting force, tool wear and surface machining condition were evaluated and analysisd and a multiple-factors interactive and regressive model was built where cutting force and surface roughness(Ra) is a function of cutting parameters to deeply understand the milling mechanism of Compacted graphite iron.
3.According to test data, the cutting parameters was optimized through optimizing multiple targets then the parameters was applied in the cylinder head machining. the application result was evaluated and the parameters was popularized.
4.Modeling simulation research was carried out based on the test data to verify the reliability of the test conclusion on the Compacted graphite iron in theory.
引文
[1]顾崇衔,机械制造工艺学,陕西科学技术出版社,1981年
[2]郑明新主编,工程材料(第二板),清华大学出版社出版,1994年
[3]张伯明,蠕墨铸铁在发动机上的应用
[4]史蒂夫.道森,蠕墨铸铁-现代柴油发动机缸套和缸盖的材料,铸造技术,2009年4月
[5]郝长文,蠕墨铸铁柴油发动机气缸体的高效率端面铣削加工,汽车工艺与材料,2009年1期
[6]美国,兰姆技术公司,蠕墨铸铁高速加工,产品与技术,2005年12月
[7]田永生,铸铁硬度与切削加工性能的关系,钢铁研究学报,1998年4月,P73—75
[8]提高铸铁车削加工效率与稳定性,机电之家,2009年11月
[9] S. Dawson,T. Schroeder,Practical Applications for Compacted Graphite Iron, Sinter Cast Inc Naperville,Illinois Paper 04-047(05).pdf, Page 1 of 9
[10]李学芳,国外刀具材料的发展近况,工具技术,1999,(3), P3～7
[11]肖诗纲,刀具材料的新发展(下),机械工程师,1994年第4版
[12]张荆门,硬质合金工业的发展[J],粉末冶金技术,2002,20(3): 140-146
[13]于传跃,黄继锋,高天军等,涂层刀具的切削特点及影响因素,机械工程师,2002,9
[14]叶伟昌,严卫平,叶毅,涂层硬质合金刀具的发展与应用,硬质合金,1998,(1),P54～57
[15]宋洁冰,李雪飞,刘桂金等,涂层硬质合金刀具及其在切削加工中的应用,光电对抗与无源干扰,2002,(3),P43～46
[16]胡红兵(译),不断发展的刀具涂层技术[J],工具展望,2008,(6): 9-12
[17]胡红兵(译),刀具创新对提高金属切削效率的作用与影响[J],工具技术, 2005, 39(12): 3
[18]刘战强,万熠,周军,高速切削刀具材料及其应用,机械工程材料,2006 ,30 (5) :1～8
[19]刘建华,邓建新,张庆余,TiAlN涂层刀具的发展及应用,工具技术,2006,40 (4) :9～13
[20]李忠厚,刘小平,徐重,刀具PVD涂层技术的发展[J],工具技术,1999,33(2): 3-6
[21]邓建新,钮平章,王景海,“软”涂层刀具的发展与应用[J],工具技术,2005,39(3): 10-12
[22] A.Berglund , C.M.Nicolesc , INVESTIGATION OF THE EFFECT OF MICROSTRUCTURES ON CGI MACHINING,Swedish Production Symposium 2007
[23] K. P. Varghese,A. K. Balaji*,Effects of tool material,tool topography and minimal quantity lubrication (MQL) on machining performance of compacted graphite iron (CGI),International Journal of Cast Metals Research 2007 VOL 20
[24]艾兴,萧虹,陶瓷刀具切削加工,北京:机械工业出版社,1988
[25]吴湘柠,我国CBN刀具材料的现状及发展趋势,机械制造,1992年第5期
[26]丁维军,张弘韬,李享德等,立方氮化硼刀具的现状与发展,机械研究与应用,1995年第4期
[27] PCBN刀具切削铸铁材料的研究进展,中国研磨网,2005年11月
[28]梁明柱,程铁仕,气缸盖机械加工工艺设计综述,山东内燃机,2004年2月
[29]党香玲,数控加工技术在气缸盖工艺中的应用,鸡西大学学报,2009年2月
[30]切削加工中CGI的挑战,工具展望,2009年
[31]肖诗纲,刀具材料及其合理选择(第二版),北京:机械工业出版社,1990
[32]邓建新,赵军,数控刀具材料选用手册,北京:机械工业出版社,2005
[33]周泽华,金属切削理论[M],北京,机械工业出版社,1992
[34]陈日曜,金属切削原理,机械工业出版社,2002年
[35]杨叔子主编,机械加工工艺师手册,机械工业出版社,2001年
[36]朱华,金属切削实用刀具技术,机械工业出版社,2002 ,P306～310
[37]陆剑中,金属切削原理与刀具,机械工业出版社,2002,P26～28
[38]温秉权,黄勇主编,金属材料手册,电子工业出版社,2009年
[39]李娟,徐宏海,袁海强,切削力测量技术现状及其发展趋势分析,现代商贸工业, 2007,(6),P180～181
[40]曹腾云,顺铣与逆铣刀齿接触长度及切削厚度的数值计算[J],南昌大学学报,1994, 16(3): 23-29
[41]方萍,何延,试验设计与统计,浙江大学出版社, 2003
[42] C.Dauglas Montgomery,实验设计与分析,汪仁官,陈荣昭译,北京,中国统计出版社,1998
[43]张幼桢,金属切削理论,机械工业出版社,1988年
[44]王加春,朱利娜,刘志平,切屑形状的研究方法及研究现状[J],工具技术,2006,40(8): 3-6
[45] B. Tasdelen1, M. Escursell, G. Grenmyr etc ,MACHINING OF GRAY CAST IRONS AND COMPACTED GRAPHITE IRON, bulent@chalmers.se
[46]刘战强,艾兴,高速切削刀具磨损表面形态研究[J ] ,摩擦学学报,2002,22
[47]李晋军,付建军,袁哲俊,CBN刀具磨损机理的研究,哈尔滨工业大学学报,1989年1月
[48] E. Abele, A. Sahm, H. Schulz,Wear Mechanism when Machining Compacted Graphite Iron,Available online 1 July 2007
[49]刘战强,艾兴,高速切削刀具磨损寿命的研究,工具技术,2001年第35期
[50]陈响明,王社权,易丹青,铸铁加工专用切削刀片的研制与应用,工具技术,2005年第39卷
[51]孟文,张济生,材料硬度对CBN刀具寿命的影响,机械工艺师,1995年NO.1
[52] Jiancheng Liu*,Kazuo Yamazaki, Machinability of Pearlitic Cast Iron With Cubic Boron Nitride(CBN) Cutting Tools, Journal of Manufacturing Science and Engineering NOVEMBER 2002
[53] Q.Jeffrey Xie,S.John Agapiou,Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods[J],Journal of Manufacturing Processes,2003,Vol.5(No.2)
[54]董跃辉,柯映林,孙杰等,铝合金厚板淬火残余应力的有限元模拟及其对加工变形的影响,航空学报,2004,25(4):429-232
[55]张士军,刘战强,刘继刚,涂层刀具切削温度研究现状,工具技术,2009第43卷
[2]郑明新主编,工程材料(第二板),清华大学出版社出版,1994年
[3]张伯明,蠕墨铸铁在发动机上的应用
[4]史蒂夫.道森,蠕墨铸铁-现代柴油发动机缸套和缸盖的材料,铸造技术,2009年4月
[5]郝长文,蠕墨铸铁柴油发动机气缸体的高效率端面铣削加工,汽车工艺与材料,2009年1期
[6]美国,兰姆技术公司,蠕墨铸铁高速加工,产品与技术,2005年12月
[7]田永生,铸铁硬度与切削加工性能的关系,钢铁研究学报,1998年4月,P73—75
[8]提高铸铁车削加工效率与稳定性,机电之家,2009年11月
[9] S. Dawson,T. Schroeder,Practical Applications for Compacted Graphite Iron, Sinter Cast Inc Naperville,Illinois Paper 04-047(05).pdf, Page 1 of 9
[10]李学芳,国外刀具材料的发展近况,工具技术,1999,(3), P3～7
[11]肖诗纲,刀具材料的新发展(下),机械工程师,1994年第4版
[12]张荆门,硬质合金工业的发展[J],粉末冶金技术,2002,20(3): 140-146
[13]于传跃,黄继锋,高天军等,涂层刀具的切削特点及影响因素,机械工程师,2002,9
[14]叶伟昌,严卫平,叶毅,涂层硬质合金刀具的发展与应用,硬质合金,1998,(1),P54～57
[15]宋洁冰,李雪飞,刘桂金等,涂层硬质合金刀具及其在切削加工中的应用,光电对抗与无源干扰,2002,(3),P43～46
[16]胡红兵(译),不断发展的刀具涂层技术[J],工具展望,2008,(6): 9-12
[17]胡红兵(译),刀具创新对提高金属切削效率的作用与影响[J],工具技术, 2005, 39(12): 3
[18]刘战强,万熠,周军,高速切削刀具材料及其应用,机械工程材料,2006 ,30 (5) :1～8
[19]刘建华,邓建新,张庆余,TiAlN涂层刀具的发展及应用,工具技术,2006,40 (4) :9～13
[20]李忠厚,刘小平,徐重,刀具PVD涂层技术的发展[J],工具技术,1999,33(2): 3-6
[21]邓建新,钮平章,王景海,“软”涂层刀具的发展与应用[J],工具技术,2005,39(3): 10-12
[22] A.Berglund , C.M.Nicolesc , INVESTIGATION OF THE EFFECT OF MICROSTRUCTURES ON CGI MACHINING,Swedish Production Symposium 2007
[23] K. P. Varghese,A. K. Balaji*,Effects of tool material,tool topography and minimal quantity lubrication (MQL) on machining performance of compacted graphite iron (CGI),International Journal of Cast Metals Research 2007 VOL 20
[24]艾兴,萧虹,陶瓷刀具切削加工,北京:机械工业出版社,1988
[25]吴湘柠,我国CBN刀具材料的现状及发展趋势,机械制造,1992年第5期
[26]丁维军,张弘韬,李享德等,立方氮化硼刀具的现状与发展,机械研究与应用,1995年第4期
[27] PCBN刀具切削铸铁材料的研究进展,中国研磨网,2005年11月
[28]梁明柱,程铁仕,气缸盖机械加工工艺设计综述,山东内燃机,2004年2月
[29]党香玲,数控加工技术在气缸盖工艺中的应用,鸡西大学学报,2009年2月
[30]切削加工中CGI的挑战,工具展望,2009年
[31]肖诗纲,刀具材料及其合理选择(第二版),北京:机械工业出版社,1990
[32]邓建新,赵军,数控刀具材料选用手册,北京:机械工业出版社,2005
[33]周泽华,金属切削理论[M],北京,机械工业出版社,1992
[34]陈日曜,金属切削原理,机械工业出版社,2002年
[35]杨叔子主编,机械加工工艺师手册,机械工业出版社,2001年
[36]朱华,金属切削实用刀具技术,机械工业出版社,2002 ,P306～310
[37]陆剑中,金属切削原理与刀具,机械工业出版社,2002,P26～28
[38]温秉权,黄勇主编,金属材料手册,电子工业出版社,2009年
[39]李娟,徐宏海,袁海强,切削力测量技术现状及其发展趋势分析,现代商贸工业, 2007,(6),P180～181
[40]曹腾云,顺铣与逆铣刀齿接触长度及切削厚度的数值计算[J],南昌大学学报,1994, 16(3): 23-29
[41]方萍,何延,试验设计与统计,浙江大学出版社, 2003
[42] C.Dauglas Montgomery,实验设计与分析,汪仁官,陈荣昭译,北京,中国统计出版社,1998
[43]张幼桢,金属切削理论,机械工业出版社,1988年
[44]王加春,朱利娜,刘志平,切屑形状的研究方法及研究现状[J],工具技术,2006,40(8): 3-6
[45] B. Tasdelen1, M. Escursell, G. Grenmyr etc ,MACHINING OF GRAY CAST IRONS AND COMPACTED GRAPHITE IRON, bulent@chalmers.se
[46]刘战强,艾兴,高速切削刀具磨损表面形态研究[J ] ,摩擦学学报,2002,22
[47]李晋军,付建军,袁哲俊,CBN刀具磨损机理的研究,哈尔滨工业大学学报,1989年1月
[48] E. Abele, A. Sahm, H. Schulz,Wear Mechanism when Machining Compacted Graphite Iron,Available online 1 July 2007
[49]刘战强,艾兴,高速切削刀具磨损寿命的研究,工具技术,2001年第35期
[50]陈响明,王社权,易丹青,铸铁加工专用切削刀片的研制与应用,工具技术,2005年第39卷
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[52] Jiancheng Liu*,Kazuo Yamazaki, Machinability of Pearlitic Cast Iron With Cubic Boron Nitride(CBN) Cutting Tools, Journal of Manufacturing Science and Engineering NOVEMBER 2002
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