CN106897484B - Method for obtaining high-efficiency low-stress grinding technological parameters of high-temperature alloy - Google Patents

Method for obtaining high-efficiency low-stress grinding technological parameters of high-temperature alloy Download PDF

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CN106897484B
CN106897484B CN201710013444.2A CN201710013444A CN106897484B CN 106897484 B CN106897484 B CN 106897484B CN 201710013444 A CN201710013444 A CN 201710013444A CN 106897484 B CN106897484 B CN 106897484B
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姚倡锋
张定华
任军学
田荣鑫
谭靓
武导侠
周征
张吉银
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Abstract

The invention discloses a method for obtaining high-efficiency low-stress grinding technological parameters of a high-temperature alloy, which is characterized by comprising the following steps of: step 1, establishing a high-temperature alloy surface integrity grinding process parameter domain, and establishing a high-temperature alloy surface integrity grinding process parameter and surface integrity characteristic relational expression; step 2, establishing a target function, performing linearization treatment, and establishing a high-temperature alloy grinding process parameter constraint condition; step 3, establishing a high-temperature alloy high-efficiency low-stress grinding process parameter optimization model to obtain high-temperature alloy high-efficiency low-stress grinding process parameters; and 4, verifying the high-temperature alloy high-efficiency low-stress grinding process parameters to obtain the final high-temperature alloy high-efficiency low-stress grinding process parameters. The invention solves the problems of large surface residual stress and low grinding efficiency in the grinding process of the traditional high-temperature alloy component.

Description

Method for obtaining high-efficiency low-stress grinding technological parameters of high-temperature alloy
Technical Field
The invention belongs to the technical field of precise and ultra-precise grinding processing, and particularly relates to a method for obtaining high-efficiency low-stress grinding process parameters of a high-temperature alloy.
Background
The high-temperature alloy is the preferred material for most hot-end parts of the aeroengine by virtue of excellent high-temperature strength, oxidation resistance, creep resistance, corrosion resistance and good fatigue property. In advanced aircraft engines, the amount of superalloy used is 40% to 60%. However, the grinding wheel has the advantages and is a genuine difficult-to-process material due to the fact that the grinding wheel is high in grinding force and grinding temperature, easy to generate adhesive wear and diffusion wear, severe in work hardening and the like in the grinding process.
At present, the known grinding process of high-temperature alloy mainly comprises the following steps: slow feed grinding, precision and ultra-precision grinding, and ultra-high speed grinding. The technological process is as follows: if the grinding allowance is not large, the coarse grinding and the fine grinding are sequentially finished on the grinding machine. If the grinding precision is higher, after the rough grinding is finished, the workpiece is cooled to room temperature, so that the stress can be released, the deformation is reduced, and finally the workpiece is finely ground to the size. The grinding processes have the characteristics and are applied in a certain field, but cracks are easy to appear during grinding, and the surface residual tensile stress is large and the residual stress layer is deep after grinding. During the service life of an aircraft engine, cracks are fatal defects causing fatigue fracture, and the service life of components is reduced due to large residual tensile stress. Therefore, the above results are not desirable. Therefore, in the process of high-temperature alloy grinding, the control of the surface residual stress must be considered.
Disclosure of Invention
The invention aims to provide a method for obtaining high-efficiency low-stress grinding technological parameters of a high-temperature alloy, which is used for solving the problems of large surface residual stress and low grinding efficiency in the grinding process of the conventional high-temperature alloy component.
The invention adopts the following technical scheme that the method for obtaining the high-efficiency low-stress grinding technological parameters of the high-temperature alloy comprises the following steps:
step 1, establishing a high-temperature alloy surface integrity grinding process parameter domain, performing an orthogonal test according to grinding process parameters in the domain, and establishing a relation between the high-temperature alloy surface integrity grinding process parameters and surface integrity characteristics:
Figure GDA0002203544690000021
wherein R isaSurface roughness, HV surface microhardness, σrIs surface residual stress, vsIs the grinding wheel speed, vwIs the speed of the member, apFor radial feed, a0、a1、a2、a3、b0、b1、b2、b3、c0、c1、c2、c3Are all constants;
step 2, establishing a target function, performing linearization treatment, and establishing a high-temperature alloy grinding process parameter constraint condition;
step 3, establishing a high-temperature alloy high-efficiency low-stress grinding process parameter optimization model according to the high-temperature alloy surface integrity grinding process parameter domain in the step 1, the objective function in the step 2 and the high-temperature alloy grinding process parameter constraint conditions, and obtaining high-temperature alloy high-efficiency low-stress grinding process parameters;
and 4, verifying the high-temperature alloy high-efficiency low-stress grinding process parameters in the step 3 to obtain the final high-temperature alloy high-efficiency low-stress grinding process parameters.
Further, the high-temperature alloy high-efficiency low-stress grinding process parameter optimization model in the step 3 specifically comprises the following steps:
wherein Q is the material removal rate per unit time, X1＝lgvw，X2＝lg(1000ap)，X3＝lgvs，X4＝lg(10af)。
Further, the specific method of step 1 is as follows:
step 1.1, establishing a high-temperature alloy surface integrity grinding process parameter domain;
step 1.2, formulating multiple groups of orthogonal test grinding technological parameters according to the high-temperature alloy surface integrity grinding technological parameter domain in the step 1.1, and processing a first test component according to each group of grinding technological parameters;
step 1.3, measuring the surface integrity characteristic parameters of each first test component in the step 1.2;
and step 1.4, establishing a relation between the grinding process parameters and the surface integrity characteristics according to the orthogonal test grinding process parameters in the step 1.2 and the surface integrity characteristic parameters in the step 1.3.
Further, the grinding process parameter domain in the step 1.1 specifically comprises grinding wheel speed, component speed, radial feed and longitudinal feed; the surface integrity characteristic parameters in step 1.3 include surface roughness, surface microhardness and surface residual stress.
Further, the specific method of step 2 is:
step 2.1, establishing an objective function:
max Q＝vwapvsaf，
wherein Q is the material removal rate per unit time, vsIs the grinding wheel speed, vwIs the speed of the member, apFor radial feed, afIs a longitudinal feed;
step 2.2, the objective function in the step 2.1 is linearized, and the objective function is converted into the problem of solving the minimum value, so that the following results are obtained:
min Q＝-X1-X2-X3-X4，
wherein, X1＝lgvw，X2＝lg(1000ap)，X3＝lgvs，X4＝lg(10af)；
Step 2.3, establishing surface integrity grinding process parameter control domain constraints:
Figure GDA0002203544690000041
step 2.4, establishing surface roughness constraint:
0.2028-0.142X1≤0；
step 2.5, establishing surface microhardness constraint;
step 2.6, establishing surface residual stress constraint:
Figure GDA0002203544690000042
further, the high-temperature alloy high-efficiency low-stress grinding process parameters in the step 3 are obtained by solving the high-temperature alloy high-efficiency low-stress grinding process parameter optimization model through an MATLAB optimization tool box.
Further, the specific verification method in step 4 is as follows:
step 4.1, according to the high-efficiency low-stress grinding process parameters of the high-temperature alloy in the step 3, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording as a first result;
step 4.2, selecting grinding process parameters according to the grinding process parameter domain of the surface integrity of the high-temperature alloy in the step 1, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording the test results as second results;
4.3, comparing the first result with the second result, and obtaining the final high-efficiency low-stress grinding process parameters of the high-temperature alloy when the material removal rate and the surface integrity characteristics in the first result are superior to those in the second result; otherwise, repeating the step 1 to the step 4 until the final high-temperature alloy high-efficiency low-stress grinding technological parameters are obtained.
The invention has the beneficial effects that: by establishing the relationship between the grinding process parameters and the surface integrity characteristics, the high-efficiency low-stress grinding process parameters of the surface integrity of the high-temperature alloy are obtained by taking high efficiency as a target and low stress as a constraint condition, thereby not only effectively preventing the generation of grinding cracks, and the residual stress of the grinding surface can be well controlled, an orthogonal method is adopted for carrying out test design, multiple linear regression analysis and MATLAB optimization tool box for solving the model, the design and analysis method is reliable, the obtained grinding process parameters are compared with the common grinding process parameters, the surface roughness of the component is about 0.2 mu m, the surface microhardness is about 560HV, the surface residual compressive stress is about-165 MPa, the material removal rate is improved by nearly 2 times, the high-efficiency low-stress grinding of the surface integrity of the high-temperature alloy is realized, the grinding efficiency and the grinding precision are greatly improved, and the requirements of high reliability and long service life of the aeroengine component are met.
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FIG. 1 is a flow chart of a method for obtaining high-efficiency low-stress grinding process parameters of the high-temperature alloy.
Detailed Description
The present invention will be described in detail with reference to the accompanying drawings and specific embodiments.
The invention discloses a method for obtaining high-efficiency low-stress grinding process parameters of a high-temperature alloy, which specifically comprises the following steps of:
step 1, establishing a high-temperature alloy surface integrity grinding process parameter domain, performing an orthogonal test according to grinding process parameters in the domain, and establishing a relation between the high-temperature alloy surface integrity grinding process parameters and surface integrity characteristics, wherein the specific method comprises the following steps:
step 1.1: according to the aviation manufacturing engineering manual, experience or literature data, a high-temperature alloy GH4169DA surface integrity grinding process parameter domain is established, wherein the grinding method adopts cylindrical grinding, the grinding wheel type adopts a single crystal corundum grinding wheel, a ceramic bond, the granularity is 80, the grinding process parameter comprises grinding wheel speed vs(unit is m/s), member speed vw(unit m/min), radial feed ap(in mm), longitudinal feed af(in mm/r), i.e. [ v ]s,vw,ap,af]The specific parameters are shown in table 1:
TABLE 1
Step 1.2: carrying out an orthogonal test according to the grinding process parameters in the high-temperature alloy GH4169DA surface integrity grinding process parameter domain established in the step 1.1: designing a plurality of groups of test parameters, wherein the plurality of groups of test parameters form an orthogonal test table, namely a table 2;
Figure GDA0002203544690000062
Figure GDA0002203544690000071
TABLE 2
The test environment is selected and tested on an MMB1420 cylindrical grinding machine, the grinding wheel shown in the table 1 is adopted as the grinding wheel, the emulsion is adopted for cooling in the test, the size of an initial component is preferably phi 30mm multiplied by 100mm, and a plurality of first test components are processed according to each group of test parameters in the table 2, namely one component is processed according to 16 groups of parameters.
Step 1.3: the surface roughness, surface microhardness and surface residual stress of each first test member processed in step 1.2 were tested:
the surface roughness is tested by adopting a TR240 surface roughness tester, the testing direction is along the axial direction, the sampling length is 0.8mm, and the evaluation length is 5.6 mm;
the surface microhardness is tested by adopting a 430SVD digital display microhardness tester, the test force is 0.5kgf, and the load retention time is 10 s;
testing the surface residual stress by adopting a Proto LXRD MG2000 residual stress testing and analyzing system, wherein the testing direction is along the axial direction, the target material Mn target is tested, the diffraction angle is 151.88 degrees, the testing current is 20mA, and the testing voltage is 25 kV;
the above test results were recorded to generate the following test results, table 3:
Figure GDA0002203544690000072
Figure GDA0002203544690000081
TABLE 3
Step 1.4: establishing a relation between grinding process parameters and surface integrity characteristics
Fitting the orthogonal test grinding process parameters in the step 1.2, namely the grinding process parameter data in the table 2, and the surface integrity characteristic parameters in the step 1.3, namely the surface integrity characteristic test data in the table 3 by adopting a multivariate linear regression analysis method, and establishing a relational expression between a surface integrity grinding process parameter domain and a surface integrity characteristic of the high-temperature alloy GH4169 DA:
Figure GDA0002203544690000082
in the present embodiment, according to the above values, the following values are obtained:
Figure GDA0002203544690000083
wherein R isaSurface roughness, HV surface microhardness, σrIs surface residual stress, vsIs the grinding wheel speed, vwIs the speed of the member, apIs radial feeding;
step 2, establishing a target function, performing linearization treatment, and establishing a high-temperature alloy grinding process parameter constraint condition:
step 2.1: establishing an objective function:
in order to achieve efficient grinding, the optimization target is that the material removal rate is highest in unit time, and the material removal rate in unit time in the grinding process is the component speed vwRadial feed apSpeed v of grinding wheelsLongitudinal feed afThus, the objective function is established:
max Q＝vwapvsaf，
wherein Q is the material removal rate per unit time;
step 2.2: linearization process objective function:
linearizing the target function by a logarithm method, and simultaneously converting the target function into a problem of solving a minimum value;
because the linear programming method requires that the variables are all non-negative values, and simultaneously considers that the absolute values of radial feed and longitudinal feed commonly used in grinding are less than 1, X is enabled to be linear logarithmically1＝lgvw，X2＝lg(1000ap)，X3＝lgvs，X4＝lg(10af) Establishing an objective function for optimizing surface integrity efficient grinding parameters of the high-temperature alloy GH4169 DA:
max Q＝X1+X2+X3+X4，
for the optimization process to be computationally convenient, the objective function can be a minimum problem, as follows:
min Q＝-X1-X2-X3-X4，
step 2.3: establishing surface integrity grinding process parameter control domain constraints:
according to the table 1, a surface integrity grinding process parameter control domain of the high-temperature alloy GH4169DA is established,
12≤vw≤22,0.005≤ap≤0.01,20≤vs≤25,1.0≤af≤2.0，
namely:
1.08≤X1≤1.34,0.69≤X2≤1,1.3≤X3≤1.398,1≤X4≤1.3，
and converted to standard form:
Figure GDA0002203544690000101
step 2.4: establishing surface roughness constraint:
the larger the surface roughness, the poorer the component performance during grinding of the high temperature alloy GH4169DA, thus setting the maximum surface roughness, preferably the maximum allowable value to 0.224 μm;
the surface roughness empirical formula of the high-temperature alloy GH4169DA is established according to the relation between the surface integrity grinding process parameter domain and the surface integrity characteristics:
Figure GDA0002203544690000102
from the exponential magnitudes of the grinding process parameters of the above formula, the workpiece speed has the greatest influence on the surface roughness, and therefore, preferably, only considering the workpiece speed, the values of the radial feed and the grinding wheel speed are preferably set to 0.006mm and 20m/s, respectively, logarithmic on both sides, and the conversion may be changed into:
0.2028-0.142X1≤0，
step 2.5: establishing surface microhardness constraint:
according to the empirical formula of the high-temperature alloy GH4169DA grinding surface microhardness of the relationship between the surface integrity grinding process parameter domain and the surface integrity characteristics, in the test parameter range, the surface microhardness is not greatly changed in the high-temperature alloy GH4169DA grinding process, so that the surface microhardness constraint is ignored in the embodiment;
step 2.6: establishing surface residual stress constraint:
in the grinding process of the high-temperature alloy GH4169DA, compressive residual stress is formed, the fatigue life is increased along with the increase of the compressive surface residual stress, and the control of the low stress is considered, therefore, the lowest compressive surface residual stress is preferably set to be 55.4MPa and the highest compressive surface residual stress is preferably set to be 200MPa, namely:
considering the component speed, the grinding wheel speed and the radial feed, respectively, the two sides are logarithmized and the transformation can be changed into:
Figure GDA0002203544690000112
and step 3: establishing a high-temperature alloy GH4169DA surface integrity high-efficiency low-stress grinding process parameter optimization model:
according to the steps 2.1 to 2.6, establishing a high-temperature alloy GH4169DA surface integrity high-efficiency low-stress grinding process parameter optimization model:
Figure GDA0002203544690000113
solving the high-temperature alloy high-efficiency low-stress grinding process parameter optimization model in the step 3 by utilizing an optimization tool box in MATLAB, and finally solving:
X1＝1.176，X2＝0.602，X3＝1.398,X41 is ═ 1; thus, vw＝15m/min，ap＝0.005mm，vs＝25m/s，af＝1mm/r。
The grinding process parameter is only used for the final procedure in the grinding process, namely fine grinding, and is used for ensuring the surface integrity of the final grinding, so that the grinding efficiency is improved while low stress is obtained.
And 4, step 4: verifying the high-temperature alloy GH4169DA high-efficiency low-stress grinding process parameters in the step 3 to obtain the final high-temperature alloy high-efficiency low-stress grinding process parameters:
step 4.1, according to the high-efficiency low-stress grinding process parameters of the high-temperature alloy GH4169DA in the step 3, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording as a first result;
step 4.2, selecting grinding process parameters according to the grinding process parameter domain of the surface integrity of the high-temperature alloy in the step 1, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording the results as second results;
the first and second results are specifically shown in table 4:
Figure GDA0002203544690000121
TABLE 4
And 4.3, comparing the first result with the second result, wherein the material removal rate and the surface integrity characteristic in the first result are superior to the material removal rate in the second resultAnd when the surface integrity is characterized, the final high-temperature alloy high-efficiency low-stress grinding process parameters are as follows: v. ofw＝15m/min，ap＝0.005mm，vs＝25m/s，af＝1mm/r；
And when the material removal rate and the surface integrity characteristics in the first result are not superior to those in the second result, repeating the steps 1 to 4 until the final high-efficiency low-stress grinding process parameters of the high-temperature alloy are obtained.
Therefore, the method for obtaining the high-efficiency low-stress grinding process parameters of the high-temperature alloy GH4169DA in the embodiment is characterized in that the grinding process parameters are optimized by establishing a relation between the grinding process parameters and the surface integrity characteristics, taking the machining efficiency as a target, taking the surface roughness, the surface microhardness and the surface residual stress as constraints, and obtaining the high-efficiency low-stress grinding process parameters of the surface integrity.
The method can be used for guiding the determination of the high-efficiency low-stress grinding process parameters of the surface integrity of the high-temperature alloy, remarkably improving the grinding surface integrity of the component, preventing the generation of grinding cracks and ensuring the fatigue life of the component.

Claims (5)

1. The method for obtaining the high-efficiency low-stress grinding technological parameters of the high-temperature alloy is characterized by comprising the following steps of:
step 1, establishing a high-temperature alloy surface integrity grinding process parameter domain, performing an orthogonal test according to grinding process parameters in the domain, and establishing a relation between the high-temperature alloy surface integrity grinding process parameters and surface integrity characteristics:
Figure FDA0002203544680000011
wherein R isaSurface roughness, HV surface microhardness, σrIs surface residual stress, vsIs the grinding wheel speed, vwIs the speed of the member, apFor radial feed, a0、a1、a2、a3、b0、b1、b2、b3、c0、c1、c2、c3Are all constants;
step 2, establishing a target function, performing linearization treatment, and establishing a high-temperature alloy grinding process parameter constraint condition;
the specific method comprises the following steps:
step 2.1, establishing an objective function:
maxQ＝vw·ap·vs·af，
wherein Q is the material removal rate per unit time, vsIs the grinding wheel speed, vwIs the speed of the member, apFor radial feed, afIs a longitudinal feed;
step 2.2, the objective function in the step 2.1 is linearized, and the objective function is converted into a problem of solving the minimum value, so that:
minQ＝-X1-X2-X3-X4，
wherein, X1＝lgvw，X2＝lg(1000ap)，X3＝lgvs，X4＝lg(10af)；
Step 2.3, establishing surface integrity grinding process parameter control domain constraints:
step 2.4, establishing surface roughness constraint:
0.2028-0.142X1≤0；
step 2.5, establishing surface microhardness constraint;
step 2.6, establishing surface residual stress constraint:
step 3, establishing a high-temperature alloy high-efficiency low-stress grinding process parameter optimization model according to the high-temperature alloy surface integrity grinding process parameter domain in the step 1, the objective function in the step 2 and the high-temperature alloy member grinding process parameter constraint conditions, and obtaining high-temperature alloy high-efficiency low-stress grinding process parameters;
the high-efficiency low-stress grinding process parameter optimization model for the high-temperature alloy specifically comprises the following steps:
Figure FDA0002203544680000023
wherein Q is the material removal rate per unit time, X1＝lgvw，X2＝lg(1000ap)，X3＝lgvs，X4＝lg(10af)，afIn order to feed in the longitudinal direction,
and 4, verifying the high-temperature alloy high-efficiency low-stress grinding process parameters in the step 3 to obtain the final high-temperature alloy high-efficiency low-stress grinding process parameters.
2. The method for obtaining the high-efficiency low-stress grinding process parameters of the high-temperature alloy as claimed in claim 1, wherein the specific method in the step 1 is as follows:
step 1.1, establishing a high-temperature alloy surface integrity grinding process parameter domain;
step 1.2, formulating multiple groups of orthogonal test grinding technological parameters according to the high-temperature alloy surface integrity grinding technological parameter domain in the step 1.1, and processing a first test component according to each group of grinding technological parameters;
step 1.3, measuring the surface integrity characteristic parameter of each first test component in the step 1.2;
and step 1.4, establishing a grinding process parameter and surface integrity characteristic relational expression according to the orthogonal test grinding process parameter in the step 1.2 and the surface integrity characteristic parameter in the step 1.3.
3. The method for obtaining high-efficiency low-stress grinding process parameters of the superalloy as claimed in claim 2, wherein the grinding process parameter domain in step 1.1 specifically includes a grinding wheel speed, a component speed, a radial feed and a longitudinal feed; the surface integrity characteristic parameters in step 1.3 include surface roughness, surface microhardness and surface residual stress.
4. The method for obtaining the high-temperature alloy high-efficiency low-stress grinding process parameters according to claim 1, wherein the high-temperature alloy high-efficiency low-stress grinding process parameters in the step 3 are obtained by solving an optimization model of the high-temperature alloy high-efficiency low-stress grinding process parameters through an optimization tool box in MATLAB.
5. The method for obtaining the high-efficiency low-stress grinding process parameters of the high-temperature alloy as claimed in claim 1, wherein the specific verification method in the step 4 is as follows:
step 4.1, according to the high-efficiency low-stress grinding process parameters of the high-temperature alloy in the step 3, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording as a first result;
step 4.2, selecting grinding process parameters according to the grinding process parameter domain of the surface integrity of the high-temperature alloy in the step 1, performing metal material removal rate and surface integrity characteristic tests in unit time, and recording the test results as second results;
4.3, comparing the first result with the second result, and obtaining the final high-efficiency low-stress grinding process parameters of the high-temperature alloy when the material removal rate and the surface integrity characteristics in the first result are superior to those in the second result; otherwise, repeating the step 1 to the step 4 until the final high-temperature alloy high-efficiency low-stress grinding technological parameters are obtained.
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