CN105243195B - A kind of Forecasting Methodology of micro- milling nickel base superalloy processing hardening - Google Patents
A kind of Forecasting Methodology of micro- milling nickel base superalloy processing hardening Download PDFInfo
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Abstract
A kind of Forecasting Methodology of micro- milling nickel base superalloy processing hardening of the present invention belongs to micro-cutting manufacture field, is related to a kind of micro- Milling Process nickel base superalloy, passes through simulation modeling and the Forecasting Methodology of theory deduction processing hardening.Forecasting Methodology to workpiece and cutter by carrying out three-dimensional macro modeling, consider material elastic-plastic constitutive relation, establish nickel base superalloy model, tool work piece friction type, metal cutting disjunctive model, export strain value under finite element simulation difference cutting parameter, again by contacting strain and the relationship of hardness, Hardness Prediction value under different cutting parameters is obtained, predicts processing hardening situation.The Forecasting Methodology mode for establishing model, which quantizes, predicts processing hardening situation, and manpower can be saved compared with testing and measuring hardness, reduces cost.Simple using the verification of Forecasting Methodology hardness, accuracy is preferable.
Description
Technical field
The invention belongs to micro-cutting manufacture fields, are related to a kind of micro- Milling Process nickel base superalloy, pass through simulation modeling
With the Forecasting Methodology of theory deduction processing hardening.
Background technology
With the progress of science and technology, the fields such as aerospace, energy source and power, biomedicine all occur micro-structure/
Part, such micro-structure/element precision requirement is high, has three-dimensional geometrical structure shape such as step surface, deep hole, thin-walled etc., has
Larger depth-to-width ratio and draw ratio, which part part, which does not require nothing more than, can bear higher operating temperature, and need to have compared with
High intensity and corrosion resistance.Nickel base superalloy Inconel 718 have high intensity, antifatigue, corrosion-resistant, high temperature resistant,
The excellent performances such as inoxidizability, be manufacture aero-engine, turbo blade, engine thermal end pieces ideal material.Ni-based height
The micro- milling technology of temperature alloy is the high efficiency technical means for preparing nickel base superalloy micro parts.But since nickel base superalloy has
There is the features such as intensity is high, viscosity is big, heat-conductive characteristic is low, large deformation can be generated in micro- milling process, so as to generate lattice distortion
Deformation, leads to processing hardening phenomenon.The intensity of workpiece, hardness and wear-resisting can be improved for the processing hardening of parts with microstructure appropriateness
Property, and excessive processing hardening is processed further causing difficulty to workpiece, particularly in the Precision Machinings such as micro- milling, cutter is small
It is prone to wear out, processing hardening leads to cutter Fast Wearing, seriously affects cutter life, processing quality, excessive processing hardening is also
It can lead to that workpiece cracks, size changes, so the research for processing hardening is extremely important.In cutting field
In, there is certain scale for processing hardening research, but most of researchs are the prediction models based on experiment, generally
Many factors can be considered to the effect tendency of processing hardening and the depth of hardened layer, it is hard after but few people process material
Degree carries out numeralization prediction.And test method is time-consuming and laborious, poor universality.Due to the development of soft project, modern analysis is soft
Part has formed scale, has had many people to be emulated using the method for finite element software to working angles, wherein someone's mould
Stress in working angles, strain, temperature, the situation of change of tool wear are intended, but using emulation mode to hard after machining
The research that degree carries out numeralization prediction is seldom.Such as N.Ben Moussa et al. 2012 are in periodical《International
Journal of Mechanical Sciences》In the paper delivered《Numerical and experimental
analysis of residual stress and plastic strain distributions in machined
stainless steel》, plastic strain is predicted by two dimensional finite element emulation mode and verifies mould with test measurement plastic strain
Then type reasonability is fitted relationship between hardness and plastic strain by experiment, and after actual processing, it should for material plasticity
It is not simple for hardness measurement to become measurement, simple, standard is verified using hardness using plastic strain verification model reasonability
True property is poor, and does not establish the numerical relation between plastic strain and hardness.
Invention content
The defects of present invention is in order to overcome the prior art considers micro- Milling Process scale effect, carries out micro- Milling Process
Finite element three-dimensional artificial using the theory relation between finite element technique and hardening, strain and hardness, establishes the Ni-based height of micro- milling
Temperature alloy predicts the model of processing hardening.Forecasting Methodology with finite element simulation technology, carries out workpiece and cutter three-dimensional first
Macromodeling considers the elastic-plastic constitutive relation of material, establishes nickel base superalloy model, tool work piece friction model, metal
Chip disjunctive model, so as to obtain the micro- Milling Processes finite element simulation of nickel base superalloy under different cutting parameters.Then,
According to the hardening curve of nickel base superalloy and vickers hardness test principle, the relationship mould of flow stress and Vickers hardness is established
Type.On the basis of finite element simulation output strain, contact strain and the relationship of hardness realize that the micro- milling of nickel base superalloy adds
The Hardness Prediction on work surface.Simple using the verification of Forecasting Methodology hardness, accuracy is preferable.
The technical solution adopted by the present invention is a kind of Forecasting Methodology of micro- milling nickel base superalloy processing hardening, using having
The first emulation technology of limit, it is characterized in that, Forecasting Methodology considers material elastoplasticity by carrying out three-dimensional macro modeling to workpiece and cutter
Constitutive relation, establishes nickel base superalloy model, tool work piece friction type, metal cutting disjunctive model, and output finite element is imitated
Strain value under very different cutting parameters, then by contacting strain and the relationship of hardness, obtain Hardness Prediction under different cutting parameters
Value predicts processing hardening situation；Forecasting Methodology is as follows：
Step 1：Micro- milling cutter model is established, will be tested with the shooting of micro- milling cutter into picture by scanning electron microscope, it will using software
Picture is depicted as micro- milling cutter physical model, imports in ABAQUS；
Step 2：Consider the conditions such as milling cutter size and cutting parameter, choose suitable dimension and establish workpiece to be machined three-dimensional mould
Type；
Step 3：Mesh generation is carried out to micro- milling cutter and workpiece, micro- milling cutter and workpiece rigid body type are set, grid is selected to draw
Divide mode and cell type；
Step 4：Material property parameter is set, and cutter is considered as rigid body, workpiece material type definition is elastoplasticity, using J-
The essential equation of the true cutting flow within materials stress and strain of C model simulation, using the chip separation criterion of J-C models as sentencing
According to simulation cutting fragment forming process；
Wherein, the constitutive model of the material is：
In formula, σYFor flow stress, A is the yield strength under reference temperature and reference strain rate, and B is strain hardening system
Number,For equivalent plastic strain, n is strain hardening exponent, and C is strain rate hardening coefficient,For equivalent plastic strain rate,To refer to strain rate, m is heating and softening index,It is related with temperature for nondimensional value；
For the separation criterion used for J-C fracture failure criterions, failure model is based on the equivalent modeling on element integral point
Property strain, invalid coefficient ω is defined as follows：
In formula,For equivalent plastic strain increment,Strain value during to be broken,
In formula, d1~d5For less than the failure constant measured under reference temperature, p/q is pressure deviatoric stress ratio, and p is compression,
Q is Von-Mises stress, and when failure parameter ω is more than 1, element integral point has reached failure criteria, and all stress of unit are equal
It is arranged to 0, unit is deleted from grid, that is, workpiece material is broken, and initially forms cutting chip；
Step 5：Cutter and part model are imported, is assembled；The relative position of micro- milling cutter and workpiece is adjusted, determines cutting
Depth and feeding distance；
Step 6：Defined analysis walks and output step, carries out explicit state analysis using ABAQUS/Explicit, is sequentially inserted into
Machining Analysis step, withdrawing analysis step, Changeover constraint analysis step set analysis step time and incremental step type, output variable respectively
It is set as equivalent plastic strain；
Step 7：Surface and contact property are defined, in contact module setting cutter constrained type, mould is penalized in contact type selection
Friction coefficient is set as 0.4 by type, then defines cutter set and with reference to point set；
Step 8：Boundary condition is defined, defines tool speed amplitude of variation curve first, is then set on reference to point set
Tool feeding speed and the speed of mainshaft are put, defines workpiece bottom and side node set, hard constraints freedom of workpiece, at each point
Constraints is set respectively in analysis step；
Step 9：Establishment task simultaneously submits operation, submits micro- milling nickel base superalloy of different cutting parameter combinations respectively
Simulation model, so as to obtain the different lower material plasticity strains of cutting parameter combination；
Step 10：After emulation, processing groove bottom on randomly choose several points, after averaging characterize surface etc.
Imitate plastic strain；
Step 11：Strain-stress relation is obtained using Hollomon formula, emulation gained equivalent plastic strain is substituted into public
Formula obtains micro- milling nickel base superalloy groove bottom stress value, and Hollomon formula are as follows：
σ=K εn (4)
In formula, σ is plasticity trus stress, and ε is plasticity true strain, and K is strength factor, and n is work-hardening exponential；σ=K εn σ
=K εn
Step 12：Using discriminate Δ judgement material elastic-plastic deformation obtained by indentation test, discriminate is as follows：
In formula, E is Young's modulus, and v is Poisson's ratio, σYFlow stress, β be in indentation test penetrator with it is unchanged
The angle that shape surface is formed；When Δ≤3, small plastic deformation occurs for material, must carry out flexibility analysis；When 3≤Δ≤30,
Plastic deformation extension；As Δ ＞ 30, no longer have any influence to hardness for most metals or alloy elastic, hardness number and
Flow stress value into stringent direct ratio, it can thus be concluded that：
H=C σe (6)
In formula, H is hardness number, and C is constant, is determined by the geometry of penetrator, takes 2.4 in the calculation；σeFor
Stress and, when using Durometer measurements, σe=σrepr+σres, σreprFor stress caused by penetrator, σresIt is original
Stress；
Step 13：Strain and hardness relation are derived by formula (4) and formula (6) and Inconel718 load-deformation curves,
It is as follows to obtain hardness number calculation formula,
H=C σe=C (σrepr+σres)=CK (εrepr+εres)n (7)
In formula, εreprFor the overstrain that pressure head introduces, value is retrieved as 0.08, ε by indentation testresFor original remnants
Strain；
Step 14：Emulation gained slot bottom plastic strain value and related coefficient are substituted into get micro- milling nickel base superalloy slot
Bottom hardness number.By establishing limit element artificial module and stress hardness relation model, the micro- Milling Process of nickel base superalloy is realized
Hardening prediction.
The beneficial effects of the invention are as follows solved first for micro-structures parts such as precision machined micro- raceway grooves, due to it
Raceway groove or slot bottom size are micron order, and penetrator can not be pressed into the problem of measuring.And to some workpiece side walls without
Method uses hardometer problem measured directly.And when using Durometer measurements, it is micron order to generate impression length and depth,
With micro- Milling Machining size in the same order of magnitude, micro-structure/part machined surface destruction cannot be ignored.Meanwhile by building
Vertical processing hardening prediction model predicts workhardness value under different cutting parameters, can be to select rational cutting parameter
Combination provides reference.It is quantized with the mode for establishing model and predicts processing hardening, people can be saved compared with testing and measuring hardness
Power reduces cost.
Description of the drawings
Nickel base superalloy stress-strain curve when Fig. 1 is cold-drawn state, wherein, abscissa is strain, and dimensionless is indulged
Coordinate is stress, unit Mpa.
Relationship between discriminates of the Fig. 2 for hardness stress variation and based on indentation test, wherein, abscissa is discriminate
Λ logarithms, ordinate are hardness and flow stress ratio, I-elastic deformation stage, II-plasticity extension phase, and III-plasticity becomes
The shape stage.
Specific embodiment
With reference to the specific implementation that the present invention will be described in detail of technical solution and attached drawing, finite element analysis software is used
ABAQUS carries out threedimensional FEM to micro- milling nickel base superalloy process, predicts slot bottom plastic strain, Ran Hougen
According to theory deduction strain and hardness relation, hardness number after being processed by emulation gained plastic strain establishes the Ni-based height of micro- milling
Temperature alloy predicts processing hardening situation model, and concrete operation step is as follows：
(1) cutter model is modeled with reference to experiment with cutter in threedimensional FEM, and day is used in modeling process of the present invention
The micro- milling cutter MX230, cutter diameter D=1mm, rounded cutting edge radius 0.002mm of this NS productions, helixangleβ=30 °, the long L=of sword
2mm.To ensure that geometrical model is identical with real tool shape and parameter, micro- milling cutter image is shot using scanning electron microscope.
Image is copied using CAD, proportionally ruler converts, and obtains actual parameter.Tool is scanned to cutter using Inventor spirals
Three-dimensional modeling, helical edges line equation are as follows：
In formula, r is milling cutter cylindrical radius,For angle of revolution,β is helix angle；
Data are substituted into, r=0.5mm, z=2mm, β=30 ° obtain
(2) workpiece geometrical model is established according to tool dimension and cutting parameter.It is established using the CAE functions that ABAQUS is carried
Size is the rectangular workpiece model of 2mm × 1.5mm × 1mm.
(3) mesh generation is carried out to micro- milling cutter.Micro- milling cutter is set as discrete rigid body, does not consider further that deformation, reduces and calculates
Amount carries out subregion grid division to cutter, for setting global seed amount in addition to cutting edge, for being set on side on cutting edge
Seed, entire cutter use triangular element, and using free mesh technology, selection rigid unit is cell type.
(4) mesh generation is carried out to workpiece.Seed on selection setting side, is suitably encrypted among workpiece, for both sides
Seed is suitably dredged, to reduce calculation amount.Due to workpiece shapes rule, hexahedron structure dividing elements technology, selection are selected
Cell type in explicit.
(5) material property parameter is set.Input density is 8190Kg/m3, elasticity modulus 2.1e+11, Poisson's ratio 0.3.
It is plastically deformed using J-C constitutive model simulation cuttings process, sequentially inputs model parameter A as 700Mpa, B 1798Mpa, C are
0.0312, n 0.9143, m 1.3.Criterion simulation cutting forming process is detached using J-C, sequentially inputs in formula (3) and fails
Constant d1~d5, respectively 0.239,0.456, -0.3,0.07,2.5.
(6) it imports workpiece and cutter model is assembled.Micro- milling cutter and workpiece are adjusted according to cutting depth and feeding distance
Relative position.
(7) defined analysis step and output step.In Step modules, it is inserted into micro- Milling Process analysis step, withdrawing analysis step, about
Beam transformational analysis walks, procedural type selection Dynamics, Explicit.
(8) defining contact property between cutter and workpiece, to penalize model, friction coefficient is set as 0.4, and it is cutter to rub secondary
Outer surface and workpiece surface.
(9) tool speed amplitude of variation curve is defined, setting feed speed and the speed of mainshaft on reference to point set, in order to
The movement of workpiece is limited, in the bottom surface of workpiece and side setting constraint.In Milling Process analysis step, micro- milling cutter rotating speed n is set
With feed speed vf, along direction of feed milling straight slot, workpiece movement speed and rotary speed are set as 0, Workpiece clamping, analysis step
Time is t=l/f (l is feeding distance, and f is feed speed)；In withdrawing analysis step, the setting speed of mainshaft is 0, feed speed
Still it is vf, clamp constraint and continue, the analysis step time is 0.001s；In constraints conversion analysis step, Workpiece clamping state stops, into
0 is set as to speed and the speed of mainshaft, workpiece movement speed and rotary speed are set as 0, and the analysis step time is 1.Setting output becomes
It measures as equivalent plastic strain.
(10) data are created in Job modules.Spindle speed 60000r/min, cutting depth are 30 μm, feed engagement
Respectively 0.5 μm/z, 0.9 μm/z, 1.1 μm/z, 1.3 μm/z.Check it is errorless after submit task, carry out finite element analysis.
(11) after the completion of emulating, the equivalent plastic strain of 40 points is randomly choosed, the equivalent modeling on surface is characterized after averaging
Property strain.
(12) according to experiment gained discriminate (5) judgement material elastic-plastic deformation, it is related to substitute into nickel-base high-temperature alloy material
Parameter, E=205Gpa, σY=1290MPa, β=22 °, v=0.30, obtain：
According to stress hardness and the relationship of discriminate, Fig. 2 is seen, obtain Δ and fall into III stage of plastic deformation, hardness number and stream
Dynamic stress value is directly proportional.
Parameter is substituted into up to hardness number, using feed engagement as 0.5 μm/z, speed of mainshaft 60000r/ by formula (7)
Min, for 30 μm of cutting-in, simulation data equivalent strain is 0.31 at this time, and hardness calculation is as follows,
H=CK (εrepr+εres)n=2.4 × 2487 × (0.310+0.08)0.153=4952MPa=495.2kg/mm2。
Claims (1)
1. a kind of Forecasting Methodology of micro- milling nickel base superalloy processing hardening, using finite element simulation technology, it is characterized in that, in advance
Survey method considers material elastic-plastic constitutive relation, establishes nickel-base high-temperature conjunction by carrying out three-dimensional macro modeling to workpiece and cutter
Golden model, tool work piece friction type, metal cutting disjunctive model export strain value under finite element simulation difference cutting parameter,
Again by contacting strain and the relationship of hardness, Hardness Prediction value under different cutting parameters is obtained, predicts processing hardening situation, prediction
Method is as follows：
Step 1：Micro- milling cutter model is established, will be tested by scanning electron microscope and shot with micro- milling cutter into picture, using software by picture
Micro- milling cutter physical model is depicted as, is imported in ABAQUS；
Step 2：Consider milling cutter size and cutting parameter condition, choose milling cutter size and establish workpiece to be machined threedimensional model；
Step 3：Mesh generation is carried out to micro- milling cutter and workpiece, micro- milling cutter and workpiece rigid body type are set, selects mesh generation side
Formula and cell type；
Step 4：Material property parameter is set, and does not need to setting material since cutter is considered as rigid body, workpiece material type definition is
Elastoplasticity really cuts the essential equation of flow within materials stress and strain using J-C modelings, with the chip of J-C models
Criterion is detached as criterion simulation cutting fragment forming process；
Wherein, the constitutive model of the material is：
In formula, σYFor flow stress, A is the yield strength under reference temperature and reference strain rate, and B is strain hardening coefficient,
For equivalent plastic strain, n is strain hardening exponent, and C is strain rate hardening coefficient,For equivalent plastic strain rate,For ginseng
Strain rate is examined, m is heating and softening index,It is related with temperature for nondimensional value；
For the separation criterion used for J-C fracture failure criterions, failure model is should based on the equivalent ductility on element integral point
Become, invalid coefficient ω is defined as follows：
In formula,For equivalent plastic strain increment,Strain value during to be broken,
In formula, d1~d5For less than the failure constant measured under reference temperature, p/q is pressure deviatoric stress ratio, and p is compression, and q is
Von-Mises stress, when failure parameter ω is more than 1, element integral point has reached failure criteria, and all stress of unit are set
0 is set to, unit is deleted from grid, that is, workpiece material is broken, and initially forms cutting chip；
Step 5：Cutter and part model are imported, is assembled；The relative position of micro- milling cutter and workpiece is adjusted, determines cutting depth
And feeding distance；
Step 6：Defined analysis walks and output step, carries out explicit state analysis using ABAQUS/Explicit, is sequentially inserted into processing
Analysis step, withdrawing analysis step, Changeover constraint analysis step set analysis step time and incremental step type, output variable to be set as respectively
Equivalent plastic strain；
Step 7：Surface and contact property are defined, in contact module setting cutter constrained type, model is penalized in contact type selection, will
Friction coefficient is set as 0.4, then defines cutter set and with reference to point set；
Step 8：Boundary condition is defined, defines tool speed amplitude of variation curve first, knife then is set on reference to point set
Have feed speed and the speed of mainshaft, define workpiece bottom and side node set, hard constraints freedom of workpiece, in each analysis step
It is middle that constraints is set respectively；
Step 9：Establishment task simultaneously submits operation, submits micro- milling nickel base superalloy emulation of different cutting parameter combinations respectively
Model, so as to obtain the different lower material plasticity strains of cutting parameter combination；
Step 10：After emulation, several points are randomly choosed in processing groove bottom, the equivalent modeling on surface is characterized after averaging
Property strain；
Step 11：Strain-stress relation is obtained using Hollomon formula, emulation gained equivalent plastic strain is substituted into formula obtains
Micro- milling nickel base superalloy groove bottom stress value, Hollomon formula are as follows：
σ=K εn (4)
In formula, σ is plasticity trus stress, and ε is plasticity true strain, and K is strength factor, and n is work-hardening exponential；
Step 12：Using discriminate Δ judgement material elastic-plastic deformation obtained by indentation test, discriminate is as follows：
In formula, E is Young's modulus, and v is Poisson's ratio, σYIt is flow stress, β is penetrator and not deformed table in indentation test
The angle that face is formed；When Δ≤3, small plastic deformation occurs for material, must carry out flexibility analysis；When 3≤Δ≤30, plasticity
Deformation extension；Work as Δ>When 30, no longer there are any influence, hardness number and flowing to hardness for most metals or alloy elastic
Thus stress value is obtained into stringent direct ratio：
H=C σe (6)
In formula, H is hardness number, and C is constant, is determined by the geometry of penetrator, takes 2.4 in the calculation；σeFor stress
With, when using Durometer measurements, σe=σrepr+σres, σreprFor stress caused by penetrator, σresFor original stress；
Step 13：Strain and hardness relation are derived by formula (4) and formula (6) and nickel base superalloy load-deformation curve, obtained
Hardness number calculation formula is as follows,
H=C σe=C (σrepr+σres)=CK (εrepr+εres)n (7)
In formula, εreprFor the overstrain that pressure head introduces, value is retrieved as 0.08, ε by indentation testresFor original overstrain；
Step 14：It substitutes into emulation gained slot bottom plastic strain value and related coefficient is hard to get micro- milling nickel base superalloy slot bottom
Angle value；By establishing limit element artificial module and stress hardness relation model, the micro- Milling Process hardening of nickel base superalloy is realized
Prediction.
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