HOVF WC-10Co4Cr涂层磨削瞬态温度场及应力场数值模拟

易军; 金滩; 邓朝晖; 周炜

doi:10.13433/j.cnki.1003-8728.20190139

HOVF WC-10Co4Cr涂层磨削瞬态温度场及应力场数值模拟

doi: 10.13433/j.cnki.1003-8728.20190139

易军^1,2,,
金滩³,
邓朝晖^1,2,
周炜^1,2

1.
湖南科技大学智能制造研究院, 湖南湘潭 411201
2.
难加工材料高效精密加工湖南省重点试验室, 湖南湘潭 411201
3.
国家高效磨削工程技术研究中心, 长沙 410082

基金项目:

湖南省教育厅科学研究项目 18C0305

详细信息

作者简介:
易军(1987-), 讲师, 博士, 研究方向为高效精密磨削, yj_hnust@163.com

中图分类号: TH162
计量
- 文章访问数: 589
- HTML全文浏览量: 218
- PDF下载量: 32
- 被引次数: 0
出版历程
- 收稿日期: 2019-03-28
- 刊出日期: 2020-03-05

Numerical Simulation of Transient Temperature Field and Stress Field in Grinding of HVOF WC-10Co4Cr Coating

Yi Jun^{1,2
,},
Jin Tan³,
Deng Zhaohui^1,2,
Zhou Wei^1,2

1.
Intelligent Manufacturing Institute, Hunan University of Science and Technology, Hu'nan Xiangtan 411201, China
2.
Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material, Hu'nan Xiangtan 411201, China
3.
National Engineering Research Centre for High Efficiency Grinding, Changsha 410082, China

摘要

摘要: 从经典热传导方程和热弹塑性力学出发，建立了磨削过程中移动热源作用超音速火焰喷涂WC-10Co4Cr涂层材料的二维传热模型和热应力模型；在考虑材料热物理参数随温度变化的基础上，利用有限元分析软件ANSYS来研究双层材料在磨削热-结构耦合作用下的瞬时温度场和应力场。数值研究结果表明，由于WC-10Co4Cr涂层热传导系数和比热容比300M钢基体大，所以温升主要停留在涂层内；磨削温度沿工件深度方向非连续分布，涂层基体结合面的温度梯度最大；由于涂层、基体材料热膨胀系数差异较大，在结合面处产生极大的热应力；磨削温度、涂层-基体结合面热应力随涂层厚度的降低而增大。开展了磨削温度测量实验，测量了不同涂层厚度时工件表面的磨削温度，对数值仿真结果进行了验证。
- 磨削 /
- 超音速火焰喷涂涂层 /
- 有限元方法 /
- 磨削温度场 /
- 磨削应力场
Abstract: Based on the classical heat conduction equation and thermoplastic mechanics, the two-dimensional heat transfer model and thermal stress model for the grinding process of High Velocity Oxygen Fuel (HVOF) WC-10Co4Cr coating under the action of moving heat source were established. On considering the temperature dependent material properties, the transient temperature field and thermal stress field were simulated via finite element method. As the thermal conductivity and specific heat capacity of WC-10Co4Cr are larger than 300 M, the temperature rise mainly stays in the coating. The grinding temperature is discontinuous along the depth direction of the workpiece, and the temperature gradient of the coating/substrate junction surface is the largest. Due to the large difference in thermal expansion coefficient between the coating and the substrate, the great thermal stress is generated at the bonding surface. The grinding temperature and thermal stress of the coating/substrate junction surface increase with the decreasing of coating thickness. The grinding temperature experiments were carried out, the surface grinding temperature with different coating thicknesses was measured and the simulation results were compared with those experimental. A good agreement was found between the FEM results and the experimental.
- grinding /
- HVOF coating /
- FEM /
- Grinding temperature field /
- grinding stress field

HTML全文

图 1 有限单元模型

下载: 全尺寸图片幻灯片

图 2 有限元仿真边界条件

下载: 全尺寸图片幻灯片

图 3 移动热流载荷加载过程

下载: 全尺寸图片幻灯片

图 4 有限元仿真过程

下载: 全尺寸图片幻灯片

图 5 磨削温度测量过程

下载: 全尺寸图片幻灯片

图 6 热电偶结构图

下载: 全尺寸图片幻灯片

图 7 热节点照片

下载: 全尺寸图片幻灯片

图 8 磨削后涂层保留厚度

下载: 全尺寸图片幻灯片

图 9 有限元仿真结果云图

下载: 全尺寸图片幻灯片

图 10 时空分布的磨削温度和热应力

下载: 全尺寸图片幻灯片

图 11 磨削温度、温度梯度沿工件深度分布

下载: 全尺寸图片幻灯片

图 12 磨削热应力、磨削温度梯度沿工件深度分布

下载: 全尺寸图片幻灯片

图 13 工件表面磨削温度随涂层厚度的变化

下载: 全尺寸图片幻灯片

图 14 涂层-基体结合面磨削温度随涂层厚度的变化

下载: 全尺寸图片幻灯片

图 15 涂层-基体结合面磨削热应力随涂层厚度的变化

下载: 全尺寸图片幻灯片

表 1 砂轮性能参数^[15]

材料	密度ρ/ (g·cm^-3)	导热率λ/ (W·(m·K)^-1)	比热容c/ (J·(kg·K)^-1)
树脂	1.25	0.125~0.7	1 591~1 758
金刚石	3.515	2 000	1 827

下载: 导出CSV

表 2 工件热物理性能^[16]

物理性能	300M钢	WC-10Co4Cr
密度ρ/(g·cm^-3)	7.74	15.5
导热率λ/(W·(m·K)^-1)	0.016 1T+21.814	121
比热容c/(J·(kg·K)^-1)	0.296T+466.714	800
弹性模量E/GPa	198	71
泊松比μ	0.32	0.3
线膨胀系数α(10^-6/K)	13.4	4.3

下载: 导出CSV

表 3 磨削参数及磨削结果

实验序号	砂轮线速度 v_s/(m·s^-1)	工件进给速度 v_w/(mm·min^-1)	磨削深度 a_p/mm	切向磨削力 F_t/N	热分配比 R_w/%	涂层厚度 h/μm	磨削温度 T/℃
						339.74	330
1	90	2 100	0.04	40	33%	339.74+2a_p	304
						339.74+4a_p	270
						233.57	482
2	90	2 800	0.06	66	33	233.57+2a_p	420
						233.57+4a_p	355
						435.29	287
3	150	2 800	0.02	23	37	435.29+2a_p	261
						435.29+4a_p	242
						424.68	426
4	150	3 500	0.04	44	36	424.68+2a_p	368
						424.68+4a_p	337

下载: 导出CSV

参考文献(16)

[1]	Zhang W C, Liu L B, Zhang M T, et al. Comparison between WC-10Co-4Cr and Cr₃C₂-25NiCr coatings sprayed on H13 steel by HVOF[J]. Transactions of Nonferrous Metals Society of China, 2015, 25(11):3700-3707 doi: 10.1016/S1003-6326(15)64011-0
[2]	周克崧.热喷涂技术替代电镀硬铬的研究进展[J].中国有色金属学报, 2004, 14(S1):182-191 http://d.old.wanfangdata.com.cn/Periodical/zgysjsxb2004z1027 Zhou K S. Progress of thermal spray coating of hard Cr instead of plating[J]. The Chinese Journal of Nonferrous Metals, 2004, 14(S1):182-191(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/zgysjsxb2004z1027
[3]	郭力, 江志顺, 尚振涛.超音速火焰喷涂WC-17Co涂层的高速磨削机理试验研究[J].中国机械工程, 2016, 27(10):1279-1286 doi: 10.3969/j.issn.1004-132X.2016.10.001 Guo L, Jiang Z S, Shang Z T. Experimental research on HVOF sprayed WC-17Co coating at high speed grinding mechanism[J]. China Mechanical Engineering, 2016, 27(10):1279-1286(in Chinese) doi: 10.3969/j.issn.1004-132X.2016.10.001
[4]	张永康, 孔德军, 冯爱新, 等.涂层界面结合强度检测研究(I):涂层结合界面应力的理论分析[J].物理学报, 2006, 55(6):2897-2900 doi: 10.3321/j.issn:1000-3290.2006.06.041 Zhang Y K, Kong D J, Feng A X, et al. Study on the determination of interfacial binding strength of coatings (I): theorctical analysis of stress in thin film binding interface[J]. Acta Physica Sinica, 2006, 55(6):2897-2900(in Chinese) doi: 10.3321/j.issn:1000-3290.2006.06.041
[5]	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 doi: 10.1016/j.ijmachtools.2008.10.002
[6]	王艳, 谢建华, 刘建国, 等.基于瑞利分布的平面磨削温度场的仿真研究[J].中国机械工程, 2015, 26(4):484-490 doi: 10.3969/j.issn.1004-132X.2015.04.011 Wang Y, Xie J H, Liu J G, et al. Research on finite element simulation of temperature field based on Rayleigh distribution in surface grinding[J]. China Mechanical Engineering, 2015, 26(4):484-490(in Chinese) doi: 10.3969/j.issn.1004-132X.2015.04.011
[7]	Nguyen T, Zhang L C. Realisation of grinding-hardening in workpieces of curved surfaces-Part 1: plunge cylindrical grinding[J]. International Journal of Machine Tools and Manufacture, 2011, 51(4):309-319 doi: 10.1016/j.ijmachtools.2010.12.006
[8]	Su J X, Ke Q X, Deng X Z, et al. Numerical simulation and experimental analysis of temperature field of gear form grinding[J]. The International Journal of Advanced Manufacturing Technology, 2018, 97(5-8):2351-2367 doi: 10.1007/s00170-018-2079-6
[9]	Shah S M, Nélias D, Zain-Ul-Abdein M, et al. Numerical simulation of grinding induced phase transformation and residual stresses in AISI-52100 steel[J]. Finite Elements in Analysis and Design, 2012, 61:1-11 doi: 10.1016/j.finel.2012.05.010
[10]	张磊, 葛培琪, 张建华, 等.40Cr钢磨削强化的试验与数值仿真[J].机械工程学报, 2006, 42(8):60-64 doi: 10.3321/j.issn:0577-6686.2006.08.010 Zhang L, Ge P Q, Zhang J H, et al. Experiment and numerical simulation of 40Cr steel in grind-hardening[J]. Chinese Journal of Mechanical Engineering, 2006, 42(8):60-64(in Chinese) doi: 10.3321/j.issn:0577-6686.2006.08.010
[11]	Haider J, Rahman M, Corcoran B, et al. Simulation of thermal stress in magnetron sputtered thin coating by finite element analysis[J]. Journal of Materials Processing Technology, 2005, 168(1):36-41 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=d7247909971b41419d45150c8b3952a0
[12]	Jin T, Stephenson D J. A study of the convection heat transfer coefficients of grinding fluids[J]. CIRP Annals, 2008, 57(1):367-370 doi: 10.1016/j.cirp.2008.03.074
[13]	Rowe W B. Thermal analysis of high efficiency deep grinding[J]. International Journal of Machine Tools and Manufacture, 2001, 41(1):1-19 doi: 10.1016/S0890-6955(00)00074-2
[14]	Jen T C, Lavine A S. A variable heat flux model of heat transfer in grinding: model development[J]. Journal of Heat Transfer, 1995, 117(2):473-478 doi: 10.1115/1.2822546
[15]	Xie X Z, Chen G Y, Li L J. Dressing of resin-bonded superabrasive grinding wheels by means of acousto-optic Q-switched pulsed Nd:YAG laser[J]. Optics & Laser Technology, 2004, 36(5):409-419
[16]	《中国航空材料手册》编辑委员会.中国航空材料手册.第1卷结构钢、不锈钢[M].2版.北京: 中国标准出版社, 2002 Editorial Committee of China Aeronautical Materials Handbook. China aeronautical materials handbook, vol 1, structural steel, stainless steel[M]. 2nd ed. Beijing: Standards Press of China, 2002(in Chinese)