切削参数对FeCrBSi合金涂层表面完整性的影响研究

摘要: 研究切削速度v_c、进给量f和刀具前角γ₀这3个因素的变化对FeCrBSi再制造涂层已加工表面质量(包括对表面粗糙度、表面形貌和残余应力再分布量)的影响规律。结果表明: FeCrBSi涂层表面粗糙度随着切削速度的增大和进给量的降低而改善。切削后已加工涂层表面出现明显的犁沟, 且沿进给方向的波峰和波谷呈明显的规律性。切削速度为60 m/min, 进给量从0.06 mm/r增加至0.12 mm/r, 涂层表层残余应力发生了由"线性分布"的残余拉应力向"勺形分布"的残余压应力转变。切削速度提高到70 m/min, 进给量的变化对涂层残余应力再分布的影响不明显。研究发现刀具前角的增大显著影响着涂层表面残余应力值, 而切削速度的增加显著影响着涂层表层最大残余压应力值。切削参数v_c=70 m/min, f=0.12 mm/r, a_p=0.2 mm, γ₀=(10°~ 15°)是FeCrBSi合金涂层已加工表面质量状态改变的临界参数。
- FeCrBSi合金涂层 /
- 表面粗糙度 /
- 表面形貌 /
- 残余应力再分布
Abstract: The effect of the cutting parameters on the surface quality of FeCrBSi alloy remanufacturing coating were explored, with emphasis on the effect of the cutting speed, feed rate and rake angle on the surface roughness, surface morphology and residual stress redistribution. The results show that surface roughness of FeCrBSi alloy coating was enhanced with the increasing of cutting speed and decreasing of feed rate, and it can be seen from topography of the machined surface has obvious furrows, and the wave peaks and troughs fluctuate regularly along the feed direction. When cutting speed was 60 m/min, the states of residual stress were changed from the linear distribution of residual tensile stress to "spoon" shape of residual compressive stress with the increasing of feed rate from 0.06 mm/r to 0.12 mm/r. The influence on the residual stress is not obvious with increasing of feed rate at a cutting speed of 70 m/min. It found that the to increase the rake angle significantly affects the residual stress, and to increase the cutting speed significantly affects the maximum residual compressive stress. So the cutting parameters, v_c=70 m/min, f=0.12 mm/r, a_p=0.2 mm, γ₀=(10°~ 15°)are the critical transition parameters for improving the surface quality.
- FeCrBSi alloy coating /
- surface roughness /
- surface topography /
- residual stress redistribution

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图 1 工件及车削试验现场

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图 2 切削用量对表面粗糙度的影响

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图 3 积屑瘤

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图 4 原位增强基颗粒

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图 5 犁沟形貌

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图 6 增强颗粒的切断和脱粘及切削表面的滑擦

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图 7 使用ToolⅠ和ToolⅡ时切削速度对残余应力沿层深再分布的影响

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图 8 使用ToolⅠ和ToolⅡ时进给量对涂层残余应力沿层深再分布的影响

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图 9 刀具前角从5°增大到15°对涂层残余应力的影响

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表 1 FeCrBSi合金各元素的质量分数 %

Fe	Cr	B	Si	Nb	Bal
80.0	5.0	5.0~13.0	1.0	3.0~5.0	≤0.3

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表 2 FeCrBSi合金力学性能

拉伸强度σ_b/MPa	屈服波度σ_s/MPa	延伸水平δ/%	冲击韧性α_k/(J·cm^-2)	强度/ GPa
4 000	325	6~9	≥34	15.8

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表 3 车削试验方案

切削速度v_c/(m·min^-1)	进给速度f/(mm·r^-1)	切削深度a_p/mm	刀具类型γ_o/(°)
60, 80	0.06, 0.12	0.2	5, 15

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