陶瓷刀具干切削奥氏体不锈钢时的切削性能研究
摘要
陶瓷刀具材料以其高硬度和良好的高温性能,在提高加工效率和刀具寿命等方面等方面有着巨大优势,因此在切削加工领域具有很好的前景。而复合陶瓷更可由不同的设计理论、基本组分和增韧机制具有不同的性能,从而满足各种材料的加工需要。奥氏体不锈钢具有韧性强、加工硬化严重和导热性差等特点,属于难加工材料,特别在断续切削、干切削等条件下容易造成刀具磨损和破损,刀具的寿命较低。本文通过干切削试验,对Al_2O_3/SiCw(AS)、Al_2O_3/(Ti,W)C(AT)和Si_3N_4/TiC(ST)陶瓷刀具切削奥氏体不锈钢时的切削性能进行了研究,希望对今后研究陶瓷材料的改性、增强材料的性能、扩大材料的范围方面具有实际应用价值。同时还对加工时切削参数对刀具切削力、断屑性能及磨损的影响做出了研究,从而对陶瓷刀具加工切削奥氏体不锈钢类难加工材料切削参数的选择提出参考。
通过正交切削试验对陶瓷刀具切削奥氏体不锈钢时的切削力进行研究,得出对切削力影响较大的切削参数是进给量和切削深度,切削速度的影响较小;发现当切削用量选择较小值时会出现背向切削力大于主切削力的现象;建立了两种陶瓷刀具的切削力经验公式;经比较得出在相同条件下,AT刀具的切削力要大于ST刀具的切削力。
通过对陶瓷刀具切削奥氏体不锈钢时的切屑宏观形态进行研究,发现在刀具允许的切削参数范围内,选择切削参数越大,刀具的断屑性能越佳,其中影响最大的切削参数是进给量。
通过单因素切削试验对陶瓷刀具切削奥氏体不锈钢时的刀具磨损进行研究,发现刀具的主要磨损形式为刀尖处磨损以及切深处的沟槽磨损;切削速度和进给量对刀尖处磨损量的影响较显著;磨粒磨损、粘结磨损和氧化磨损是刀具的主要磨损机制;AS刀具和ST刀具在高速下切削时切深处的沟槽磨损造成刀具破损;另外试验中Al_2O_3基陶瓷刀具表现出了优于Si_3N_4陶瓷刀具的抗磨损性能。
Ceramic tools materials have huge advantages in improving machining efficiency and tool life, because of its high hardness and well high-temperature performances. Therefore this kind of tool materials is promising in high-speed machining. Composite ceramic materials can be various in property, according to different design theorys、basic components and toughening mechanisms, in need of machining various workpiece materials. Austenitic stainless steels are difficult to machine, due to their high toughness、serious work hardening and bad thermal conductivity. They can easily result in tool wear and damage, reduce of tool life, especially in interrupted cutting and dry cutting. Cutting performances of Al_2O_3/SiCw(AS)、Al_2O_3/(Ti,W)C(AT)and Si_3N_4/TiC(ST)ceramic tools in machining austenitic stainless steels were researched through dry cutting experiment, in the hope that it’s valuable in developing property of ceramic materials and expand the scope of them. The influence of cutting parameters on cutting force、chip breaking and wear were also studied, to give suggestion on selecting cutting parameters of ceramic tools in machining hard-to-cut materials like austenitic stainless steels.
The results of cutting forces of the orthogonal cutting experiment indicate that: feed rate and cutting depth have more significant effects on cutting forces than cutting velocity; Radial force is greater than main force occasionally while machining in low cutting parameters; Emprical formula of cutting force of two ceramic tools when machining austenitic stainless steels were created.
Through the research on the shape of chips, found out that the performance in chip breaking is better when high parameters are selected whthin the bounds of cutting parameters, and feed rate has the most significant effect on chip breaking.
Researched on the wear of ceramic tools in cutting austenitic stainless steels through experiment of single factor, the results indicate that, wear in tool nose and notch wear at depth of cut line are the major pattern of tools wear; Cutting velocity and feed rate have significant influence in the wear of tool nose; The predominant wear mechanism are abrasive、adhension and oxidation; AS and ST tools would be worn causing by the notch wear when machining in high velocity; Al_2O_3 based tools show better performance in resistance to wear than Si_3N_4 based tools.
通过正交切削试验对陶瓷刀具切削奥氏体不锈钢时的切削力进行研究,得出对切削力影响较大的切削参数是进给量和切削深度,切削速度的影响较小;发现当切削用量选择较小值时会出现背向切削力大于主切削力的现象;建立了两种陶瓷刀具的切削力经验公式;经比较得出在相同条件下,AT刀具的切削力要大于ST刀具的切削力。
通过对陶瓷刀具切削奥氏体不锈钢时的切屑宏观形态进行研究,发现在刀具允许的切削参数范围内,选择切削参数越大,刀具的断屑性能越佳,其中影响最大的切削参数是进给量。
通过单因素切削试验对陶瓷刀具切削奥氏体不锈钢时的刀具磨损进行研究,发现刀具的主要磨损形式为刀尖处磨损以及切深处的沟槽磨损;切削速度和进给量对刀尖处磨损量的影响较显著;磨粒磨损、粘结磨损和氧化磨损是刀具的主要磨损机制;AS刀具和ST刀具在高速下切削时切深处的沟槽磨损造成刀具破损;另外试验中Al_2O_3基陶瓷刀具表现出了优于Si_3N_4陶瓷刀具的抗磨损性能。
Ceramic tools materials have huge advantages in improving machining efficiency and tool life, because of its high hardness and well high-temperature performances. Therefore this kind of tool materials is promising in high-speed machining. Composite ceramic materials can be various in property, according to different design theorys、basic components and toughening mechanisms, in need of machining various workpiece materials. Austenitic stainless steels are difficult to machine, due to their high toughness、serious work hardening and bad thermal conductivity. They can easily result in tool wear and damage, reduce of tool life, especially in interrupted cutting and dry cutting. Cutting performances of Al_2O_3/SiCw(AS)、Al_2O_3/(Ti,W)C(AT)and Si_3N_4/TiC(ST)ceramic tools in machining austenitic stainless steels were researched through dry cutting experiment, in the hope that it’s valuable in developing property of ceramic materials and expand the scope of them. The influence of cutting parameters on cutting force、chip breaking and wear were also studied, to give suggestion on selecting cutting parameters of ceramic tools in machining hard-to-cut materials like austenitic stainless steels.
The results of cutting forces of the orthogonal cutting experiment indicate that: feed rate and cutting depth have more significant effects on cutting forces than cutting velocity; Radial force is greater than main force occasionally while machining in low cutting parameters; Emprical formula of cutting force of two ceramic tools when machining austenitic stainless steels were created.
Through the research on the shape of chips, found out that the performance in chip breaking is better when high parameters are selected whthin the bounds of cutting parameters, and feed rate has the most significant effect on chip breaking.
Researched on the wear of ceramic tools in cutting austenitic stainless steels through experiment of single factor, the results indicate that, wear in tool nose and notch wear at depth of cut line are the major pattern of tools wear; Cutting velocity and feed rate have significant influence in the wear of tool nose; The predominant wear mechanism are abrasive、adhension and oxidation; AS and ST tools would be worn causing by the notch wear when machining in high velocity; Al_2O_3 based tools show better performance in resistance to wear than Si_3N_4 based tools.
引文
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[4]于晓东.陶瓷刀具用A1_2O_3基复合材料的制备[硕士学位论文].东北大学, 2009.
[5]邓建新,艾兴. A1_2O_3—TiB2陶瓷刀具材料的研制及其耐磨性能研究.现代技术陶瓷: 1994, (2):222-225.
[6]邓建新,艾兴. A1_2O_3-TiB2陶瓷刀具材料的切削性能研究.硬质合金: 1994, 11(4):8-13.
[7]邓建新,李兆前等. A1_2O_3-TiB。陶瓷刀具材料的特性及其应用.工具技术:1994, 28(9):34-37.
[8]邓建新,张希华等. TiB2增强A1_2O_3陶瓷刀具高速干切削摩擦磨损性能.摩擦学学报: 2004, 24(3):197-201.
[9] S.R. Choi, N.P. bansal. Strength and fracture toughness of Zirconia/alumina composites for solid oxide fuel cells. Ceramic. engineering. Sci. Proc. 2002, 23(3):741-750.
[10]袁训亮, Al_2O_3/TiC/WC纳米复合陶瓷刀具的研制及切削性能[硕士学位论文].济南:山东大学, 2008.
[11]刘晶,沈世妃等.先进陶瓷刀具材料的发展与应用.中国材料科技与设备: 2008, (2):5-10.
[12]邓建新,艾兴,姜积中. A1_2O_3-SiCw陶瓷刀具材料中晶须最佳含量及其对刀具抗破损性能的影响.山东工业大学报: 1995, 25(3):272-277
[13]黄传真,新刚复相陶瓷刀具材料的研制及切削可书性研究,山东[业大学博十学位论文],1994.
[14] Ai Xing, Zhao Jun, Huang Chuanzhen, Zhang Jianhua. Development of an advanced ceramic tool material-functionally gradient cutting ceramics. Materials Science and Engineering: 1998, 248 (1-2):125–131
[15]康志伯.镍基高温合金的切削性能及切削参数优化[硕士学位论文].北京:北方工业大学, 2009.
[16] Deng Jianxin, Liu Lili. Failure mechanisms of TiB2 particle and SiC whisker reinforced Al_2O_3 ceramic cutting tools when machining nickel-based alloys. International Journal of Machine Tools & Manufacture: 2005, (45):1393–1401.
[17] L.Li, N.He等. High speed cutting of Inconel with coated carbide and ceramic incerts. Journal of materials processing technology: 2002, (129):127-130.
[18]谢国如,张兴国.氮化硅陶瓷刀具的性能及其应用.工具技术: 2007, 41(2):78-28.
[19]李文龙.高锰钢ZGMn13的切削和刀具磨损研究.煤矿机电: 1998, (6):22-23.
[20]张增志,曹鹏等.复合Si_3N_4刀具切削高锰钢时的磨损、破损机理,润滑与密封: 2003(6):58-60.
[21] A. Senthil Kumar, A. Raja Durai. Machinability of hardened steel using alumina based ceramic cutting tools. International Journal of Refractory Metals & Hard Materials: 2003, (21):109-117.
[22]俞靖,汤铭权等.陶瓷刀具切削淬硬钢的试验研究.硬质合金: 1991, 8(3):39-44.
[23]刘晓东,许耀东.不锈钢的切削研究.机械: 2005, 10.
[24]唐纳得著,顾守仁,周有得译.不锈钢手册.北京机械工业出版社, 1987.
[25]王继梅.不锈钢.1Cr18NigTi的高速车削技术试验研究[硕士学位论文].济南:山东大学, 2004.
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