ISSN   1004-0595

CN  62-1224/O4

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取向型微沟槽高速球铣加工制备方法及其减摩性能研究

Manufacturing Method and Antifriction Performance of Oriented Micro-Groove Produced by High SpeedBall-End Milling Process

  • 摘要: 探究直接利用高速球铣加工工艺制备取向型表面微沟槽织构的方法,并对该类型表面微织构的减摩性能进行研究. 鉴于高速球铣加工工艺走刀路径灵活可变、表面材料残留几何尺寸与分布形态具备可控性的特点,利用Matlab仿真对高速球铣加工表面形貌进行预测,通过高速球铣加工试验验证仿真结果,并基于流体动压润滑理论,结合Fluent流体仿真分析与高速环-块摩擦磨损试验,对该类型表面微织构的减摩性能进行分析. 当切削参数选用径向切深明显大于每齿进给量的组合时,高速球铣加工表面残留材料能够形成明显的微沟槽形貌,且微沟槽特征的取向可由球头铣刀的走刀路径进行控制;微沟槽承载能力与其取向密切相关,随着微沟槽取向角由90°减小至20°,负压区与正压区范围呈现扩大趋势,油膜内逆流效应逐渐减弱,动压效应逐渐增强,微沟槽承载能力提高了20.64%,表面摩擦系数由0.02845降低至0.02165;然而,当取向角过小时,负压区与正压区的范围过小,不能形成有效的收敛楔,微沟槽承载能力下降,表面摩擦系数上升. 通过高速球铣加工工艺能够实现取向型表面微沟槽织构的可控制备,且该类表面的减摩性能与取向角α密切相关,在本文研究范围内,取向角为20°时表现出最小的摩擦系数与最高的油膜承载力. 本文研究结果可为表面织构造型方法提供一种新思路,能够为满足零件表面的减摩需求提供很好的解决方法.

     

    Abstract: Due to the structure characteristics and the moving way of ball-end milling cutter during ball-end milling process, regularly distributed residual material would be introduced on the high speed ball-end milled surface. This study aimed at directly utilizing the regularly distributed residual material to generate oriented micro-groove features on the high speed ball-end milled surface and investigate the anti-friction performance of this kind of surface texture. On the one hand, in view of the flexible cutting tool path during high-speed ball milling process and the controllable geometric size and distribution of the surface residual material, the way of how to generate oriented micro-groove through high-speed ball-end milling technology was illustrated at length by combining topography simulation and high speed ball-end milling tests. The workpiece material chosen in this study was cold working die steel Cr12MoV with hardness about HRC 59. Milling tests were carried on a five-axis high speed machining center DMU 60P duoblock. On the other hand, the anti-friction property of ball-end milled surface with micro-groove features was evaluated by using fluid simulation analysis and high-speed ring-on-block friction and wear tests based on hydrodynamic lubrication theory. The main research results could be summarized into the following three aspects. Firstly, micro-groove features could be generated on the high speed ball-end milled surface in the case of radial depth of cut obviously larger than feed per tooth and the orientation of surface micro-grooves could be controlled conveniently by adjusting the cutting tool path. Secondly, the surface bearing capacity was closely related to the orientation of micro-grooves. As the orientation angle of micro-grooves decreased from 90° to 20°, the bearing capacity of micro-grooves increased by 20.64% and the surface friction coefficient decreased from 0.028 45 to 0.021 65. It was attributed to combined action of the wedging effect and the reverse flow phenomenon occurred during the sliding friction process. With the decrease of orientation angle, the range of negative pressure zone and positive pressure zone were strengthened. Consequently, the reverse flow phenomenon in the oil film was gradually weakened and the dynamic pressure effect was gradually enhanced. This was responsible for the improvement of anti-friction property of high speed ball-end milled surface with micro-groove features. Lastly, the surface bearing capacity decreased when an excessively small orientation angle was selected during ball-end milling process. This was because the range of negative and positive pressure zones was too small to form an effective converging wedge on this condition. Taken together, it was feasible to use high speed ball-end milling technology to fabricate oriented surface micro-grooves. Furthermore, the anti-friction performance of this kind of surfaces closely related to the orientation angle. In terms of the ability to reduce friction coefficient, the optimal anti-friction performance was obtained when the orientation angle was set as 20° during high speed ball-end milling process within the angle range of this study. The findings of this paper could not only provide a new fabrication method for surface texture, but also have certain guiding significance for the manufacture of component surfaces with anti-friction performance requirements in actual production.

     

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