锯齿形切屑形成过程根切试验研究

王风奇; 李嫚; 赵敏

doi:10.13433/j.cnki.1003-8728.20220140

锯齿形切屑形成过程根切试验研究

doi: 10.13433/j.cnki.1003-8728.20220140

大连理工大学机械工程学院，辽宁大连　116024

详细信息

作者简介:
王风奇（1996−），硕士研究生，研究方向为超硬刀具及先进材料切削加工，wangfengqi1996@163.com

通讯作者:
李嫚，副教授，硕士生导师，硕士，liman@dlut.edu.cn

中图分类号: TG514
计量
- 文章访问数: 98
- HTML全文浏览量: 47
- PDF下载量: 14
- 被引次数: 0
出版历程
- 收稿日期: 2021-10-23
- 刊出日期: 2023-11-30

Experimental Study on Formation Process of Saw-toothChip in Root Cutting

School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, Liaoning, China

摘要

摘要: 通过根切试验获得了大量锯齿形切屑根部样本，对样本进行金相处理之后得到了清晰的锯齿形切屑根部组织图片，基于切屑根部组织的变形特征，分析了锯齿形切屑的形成过程及机理，并建立了锯齿形切屑形成过程模型。研究结果表明：锯齿形切屑形成过程可分为第1变形区内剪切挤压变形积累和初步剪切面的形成阶段、切屑自由表面与切削层自由表面分离即剪切面的形成阶段、第1和第2变形区内锯齿单元发生整体集中剪切滑移阶段；锯齿形切屑的形成是由于第1变形区内靠近刀尖处材料发生热塑性失稳导致；绝热剪切带内部和切削层表面处有裂纹产生，裂纹产生于锯齿单元整体剪切滑移阶段，并且靠近切削层表面处更容易产生裂纹。
- 根切试验 /
- 锯齿形切屑 /
- 形成过程 /
- 热塑性失稳 /
- 剪切滑移
Abstract: A large number of root samples of saw-tooth chip are obtained by using the root cutting test, the clear pictures of saw-tooth chip root microstructure are obtained after metallographic processing. Based on the deformation of the chip root microstructure, the formation process and mechanism of saw-tooth chip are analyzed, and the model for saw-tooth chip formation process is established. The results show that the saw-tooth chip formation process can be divided into the accumulation of shear extrusion deformation and formation of initial shear plane in the first deformation zone, the separation of chip free surface from cutting layer free surface and formation of shear plane, the saw-tooth element overall shear slip in the first and second deformation zone. Formation of the saw-tooth chip is caused by the thermoplastic instability of the material near the tool tip in the first deformation zone. There are the cracks in the adiabatic shear band and on the surface of the cutting layer. The cracks are generated in the overall shear slip stage of the saw-tooth element, and the cracks are more likely to occur near the surface of the cutting layer.
- root cutting test /
- saw-tooth chip /
- formation process /
- thermoplastic instability /
- shear slip

HTML全文

图 1 弹簧式快速落刀装置

Figure 1. Spring-loaded quick-drop device

下载: 全尺寸图片幻灯片

图 2 装置受力简图

Figure 2. Force of the device

下载: 全尺寸图片幻灯片

图 3 刀具示意图

Figure 3. Cutting tool diagram

下载: 全尺寸图片幻灯片

图 4 工件切槽处理

Figure 4. Workpiece grooving

下载: 全尺寸图片幻灯片

图 5 切屑根部样本

Figure 5. Chip root sample

下载: 全尺寸图片幻灯片

图 6 金相试样制备

Figure 6. Metallographic specimen preparation

下载: 全尺寸图片幻灯片

图 7 金相处理结果

Figure 7. Metallurgical processing results

下载: 全尺寸图片幻灯片

图 8 基体金相组织图

Figure 8. Metallographic organisation of the basis material

下载: 全尺寸图片幻灯片

图 9 锯齿单元形成第1阶段根部组织图

Figure 9. Organisation of the roots in the first stage of serratedunit formation

下载: 全尺寸图片幻灯片

图 10 锯齿单元形成第2阶段根部组织图

Figure 10. Organisation of the roots in the second stage ofserrated unit formation

下载: 全尺寸图片幻灯片

图 11 锯齿单元形成第3阶段根部组织图

Figure 11. Organisation of the roots in the third stage ofserrated unit formation

下载: 全尺寸图片幻灯片

图 12 裂纹现象

Figure 12. Crack phenomenon

下载: 全尺寸图片幻灯片

图 13 锯齿形切屑形成过程3阶段模型

Figure 13. Model of the three-stages of sawtooth chip formation process

下载: 全尺寸图片幻灯片

表 1 Ti6Al4V的力学性能

Table 1. Mechanical properties of Ti6Al4V

屈服强度/
MPa 拉伸强度/
MPa 弹性模量/
GPa 延长率/% 硬度/
HB

896 985 118 10 313

下载: 导出CSV

参考文献(16)

[1]	李嫚, 王帅康, 程职玲, 等. 基于ABAQUS的镍基高温合金锯齿形切屑演变过程及机理研究[J]. 工具技术, 2019, 53(1): 36-42. doi: 10.16567/j.cnki.1000-7008.20190114.004 LI M, WANG S K, CHENG Z L, et al. Study on mechanism and evolution of serrated-chip of Ni-base superalloy based on ABAQUS[J]. Tool Engineering, 2019, 53(1): 36-42. (in Chinese) doi: 10.16567/j.cnki.1000-7008.20190114.004
[2]	何振中. 基于ABAQUS的锯齿形切屑形成机理分析与实验研究[J]. 机床与液压, 2020, 48(18): 70-74. doi: 10.3969/j.issn.1001-3881.2020.18.010 HE Z Z. Mechanism analysis and experimental study of serrated chip formation based on ABAQUS[J]. Machine Tool & Hydraulics, 2020, 48(18): 70-74. (in Chinese) doi: 10.3969/j.issn.1001-3881.2020.18.010
[3]	刘东. TC4钛合金切削中切屑塑性变形分析[J]. 宇航材料工艺, 2017, 47(4): 71-74. doi: 10.12044/j.issn.1007-2330.2017.04.016 LIU D. Analysis of chip plastic deformation during machining of titanium alloy TC4[J]. Aerospace Materials & Technology, 2017, 47(4): 71-74. (in Chinese) doi: 10.12044/j.issn.1007-2330.2017.04.016
[4]	何光春, 庄凯. 高速切削淬硬AISIH13锯齿形切屑形成机理研究[J]. 模具工业, 2020, 46(2): 66-71. doi: 10.16787/j.cnki.1001-2168.dmi.2020.02.016 HE G C, ZHUANG K. Research on formation mechanism of saw-tooth chip in high-speed cutting hardening AISIH13[J]. Die & Mould Industry, 2020, 46(2): 66-71. (in Chinese) doi: 10.16787/j.cnki.1001-2168.dmi.2020.02.016
[5]	赖曲芳, 付鹏, 胡淑芬. Ti6A14V高效切削加工中绝热剪切带内微观组织演变及其形成机制[J]. 科学技术与工程, 2019, 19(5): 88-93. doi: 10.3969/j.issn.1671-1815.2019.05.013 LAI Q F, FU P, HU S F. Microstructure evolution and formation mechanism of adiabatic shear band in Ti6A14V high efficiency cutting process[J]. Science Technology and Engineering, 2019, 19(5): 88-93. (in Chinese) doi: 10.3969/j.issn.1671-1815.2019.05.013
[6]	庆振华, 左敦稳, 杨海东, 等. 弹簧式快速落刀研究硬态42CrMo锯齿形切屑[J]. 中国机械工程, 2016, 27(3): 308-314. doi: 10.3969/j.issn.1004-132X.2016.03.005 QING Z H, ZUO D W, YANG H D, et al. Research on hardened 42CrMo saw-tooth chip by trial with spring type quick-stop device[J]. China Mechanical Engineering, 2016, 27(3): 308-314. (in Chinese) doi: 10.3969/j.issn.1004-132X.2016.03.005
[7]	殷继花, 林有希, 孟鑫鑫, 等. 航空铝合金7075-T651高速铣削锯齿形切屑的形成机理研究[J]. 表面技术, 2019, 48(5): 275-285. doi: 10.16490/j.cnki.issn.1001-3660.2019.05.039 YIN J H, LIN Y X, MENG X X, et al. Formation mechanism of sawtooth chip in high speed milling of aeronautical aluminum alloy 7075-T651[J]. Surface Technology, 2019, 48(5): 275-285. (in Chinese) doi: 10.16490/j.cnki.issn.1001-3660.2019.05.039
[8]	MENG X X, LIN Y X. Chip morphology and cutting temperature of ADC12 aluminum alloy during high-speed milling[J]. Rare Metals, 2021, 40(7): 1915-1923. doi: 10.1007/s12598-020-01486-2
[9]	TURLEY D M, DOYLE E D, RAMALINGAM S. Calculation of shear strains in chip formation in titanium[J]. Materials Science and Engineering, 1982, 55(1): 45-48. doi: 10.1016/0025-5416(82)90082-9
[10]	LI J Q, XU B C. Study on adiabatic shearing sensitivity of titanium alloy in the process of different cutting speeds[J]. The International Journal of Advanced Manufacturing Technology, 2017, 93(5): 1859-1865.
[11]	HOU Z B, KOMANDURI R. On a thermomechanical model of shear instability in machining[J]. CIRP Annals, 1995, 44(1): 69-73. doi: 10.1016/S0007-8506(07)62277-X
[12]	苏国胜. 高速切削锯齿形切屑形成过程与形成机理研究[D]. 济南: 山东大学, 2011. SU G S. Evolution and mechanisms of saw-tooth chip formation in high-speed machining[D]. Ji'nan: Shandong University, 2011. (in Chinese)
[13]	段春争. 正交切削高强度钢绝热剪切行为的微观机理研究[D]. 大连: 大连理工大学, 2005. DUAN C Z. Study on microcosmic mechanism of adiabatic shear behavior in orthogonal cutting of high strength steel[D]. Dalian: Dalian University of Technology, 2005. (in Chinese)
[14]	王雨溥, 李嫚, 裴江涛. 钛合金切削性能及绝热剪切带微观形态研究[J]. 工具技术, 2017, 51(11): 25-29. doi: 10.3969/j.issn.1000-7008.2017.11.006 WANG Y P, LI M, PEI J T. Reseach on cutting performance and micro-morphology of adiabatic shear band in cuting titanium alloy[J]. Tool Engineering, 2017, 51(11): 25-29. (in Chinese) doi: 10.3969/j.issn.1000-7008.2017.11.006
[15]	程职玲, 李嫚, 周锡宝, 等. 基于ABAQUS镍基高温合金锯齿形切屑形成过程的有限元模拟[J]. 现代制造工程, 2016(6): 99-103. doi: 10.16731/j.cnki.1671-3133.2016.06.020 CHENG Z L, LI M, ZHOU X B, et al. Finite element simulation about the serrated-chip formation process of Ni-base superalloy based on ABAQUS[J]. Modern Manufacturing Engineering, 2016(6): 99-103. (in Chinese) doi: 10.16731/j.cnki.1671-3133.2016.06.020
[16]	WANG S T, ZHANG Y C, GOU W D, et al. Research on improvement of merchant shear angle model[J]. Advanced Materials Research, 2014, 894: 192-200. doi: 10.4028/www.scientific.net/AMR.894.192