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浙江大学学报(工学版)
浙江大学学报(工学版)  2024, Vol. 58 Issue (4): 761-771    DOI: 10.3785/j.issn.1008-973X.2024.04.011
机械工程、能源工程     
考虑材料形变的旋风铣削螺纹工件表面粗糙度建模
刘超1,2,3(),黄尊鹏1,黄绍服1,2
1. 安徽理工大学 机电工程学院，安徽 淮南 232001
2. 安徽理工大学 环境友好材料与职业健康研究所，安徽 芜湖 241003
3. 重庆大学 机械传动国家重点实验室，重庆 400030
Surface roughness modeling of thread workpieces in whirlwind milling considering material deformation
Chao LIU1,2,3(),Zunpeng HUANG1,Shaofu HUANG1,2
1. School of Mechanical and Electrical Engineering, Anhui University of Science and Technology, Huainan 232001, China
2. Institute of Environment-friendly Materials and Occupational Health, Anhui University of Science and Technology, Wuhu 241003, China
3. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030, China
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摘要：

表面粗糙度对工件的耐磨性、疲劳强度和接触刚度有重要影响，在金属切削过程中，表面粗糙度受到工件材料形变的影响. 根据赫兹弹性接触理论，建立工件材料形变的弹性回复高度模型. 基于摩擦磨损计算原理，提出工件材料形变的塑性变形高度模型. 分析刀具-工件接触运动，建立工件表面的残留高度模型. 结合工件材料形变和残留高度的影响，建立滚珠丝杠旋风铣削表面粗糙度理论模型. 通过旋风铣削试验验证表面粗糙度模型，结果表明理论模型值与试验值吻合良好. 分析切削参数（切削速度、最大切削深度和刀具个数）对表面粗糙度的影响，揭示工件材料形变与表面粗糙度的关系.
关键词： 表面粗糙度;  材料形变;  旋风铣削;  滚珠丝杠;  塑性变形;  弹性回复    
Abstract:

Surface roughness has an important influence on wear resistance, fatigue strength and contact stiffness of the workpiece. In the process of metal cutting, the surface roughness is greatly affected by the deformation of the workpiece material. An elastic recovery height model for workpiece material deformation was established based on the Hertz elastic contact theory, and a plastic deformation height model for workpiece material deformation was proposed based on the calculation principle of friction and wear. A residual height model of the workpiece surface was established by analyzing the contact motion between the tool and the workpiece. A theoretical model for surface roughness of ball screw whirlwind milling was established based on the influence of workpiece material deformation and residual height. The surface roughness model was validated through whirlwind milling experiments, and results showed that the theoretical model values were in good agreement with the experimental values. The influence of cutting parameters (cutting speed, maximum cutting depth, and number of tools) on surface roughness was analyzed. The relationship between deformation of workpiece materials and surface roughness was revealed.
Key words: surface roughness    material deformation    whirlwind milling    ball screw    plastic deformation    elastic recovery
收稿日期: 2023-04-14 出版日期: 2024-03-27
CLC:  TG 501  
基金资助: 国家自然科学基金资助项目（52205321，52275228）；安徽省科技重大专项资助项目（202203f07020008）；安徽理工大学环境友好材料与职业健康研究院（芜湖）资助项目（ALW2021YF06）.
作者简介: 刘超（1988—），男，讲师. 从事切削加工工艺与系统研究. orcid.org/0000-0002-4749-5499. E-mail：liuchaomech@163.com
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引用本文:

刘超,黄尊鹏,黄绍服. 考虑材料形变的旋风铣削螺纹工件表面粗糙度建模[J]. 浙江大学学报(工学版), 2024, 58(4): 761-771.

Chao LIU,Zunpeng HUANG,Shaofu HUANG. Surface roughness modeling of thread workpieces in whirlwind milling considering material deformation. Journal of ZheJiang University (Engineering Science), 2024, 58(4): 761-771.

链接本文:

https://www.zjujournals.com/eng/CN/10.3785/j.issn.1008-973X.2024.04.011    或    https://www.zjujournals.com/eng/CN/Y2024/V58/I4/761

图 1  工件材料的形变区域[32]
图 2  工件材料的形变[33]
图 3  旋风铣削过程
图 4  刀具-工件接触运动
图 5  残留高度形成机理
图 6  轮廓最大高度
工况v/(m·min?1)Dc/mmNt工况v/(m·min?1)Dc/mmNt
1600.06361400.083
21000.06371400.103
31400.06381400.062
41800.06391400.064
51400.043101400.066
表 1  切削参数
参数数值参数数值
几何参数：热膨胀系数/(℃?1)11.9×10?6
轴向节距/mm10.00比热容/(J·kg?1·℃?1)476.975
工件外径/mm62.05Johnson-Cook参数[47]：
齿根圆直径/mm57.95A/MPa2482.4
螺旋角/(°)2.5B/MPa1498.5
热物理参数[46]：C0.027
密度/(g·mm?3)7.81×10?3n0.66
弹性模量/GPa210m0.19
泊松比0.3Tm/℃1 487
导热系数/(W·mm?1·℃?1)4.66×10?2——
表 2  工件的几何和物理参数
参数数值参数数值
热物理参数[48]：比热容/( J·kg?1·℃?1)750
密度/( g·mm?3)4.28×10?3几何参数：
弹性模量/GPa587前角/(°)0
泊松比0.13后角/(°)9
导热系数/( W·mm?1·℃?1)4.4×10?2刀尖圆弧半径/mm3.3
热膨胀系数/(℃?1)4.7×10?6刀具倒圆半径/mm0.08
表 3  刀具的几何和物理参数
图 7  表面粗糙度试验验证
μm
工况Ra1Ra2Ra3
10.700 00.708 10.698 2
20.668 70.689 40.664 6
30.598 10.616 00.584 5
40.635 40.605 80.607 6
50.588 40.563 80.569 8
60.684 60.645 70.624 8
70.759 80.731 60.722 6
80.593 40.609 80.579 2
90.598 40.612 70.582 6
100.598 10.607 00.578 5
表 4  旋风铣削试验中工件的表面粗糙度
图 8  表面粗糙度的试验值和理论值
图 9  切削速度对表面粗糙度的影响
图 10  最大切削深度对表面粗糙度的影响
图 11  刀具个数对表面粗糙度的影响
图 12  塑性变形高度和表面粗糙度随切削力的变化情况
图 13  塑性变形高度对表面粗糙度的影响
图 14  弹性回复高度和表面粗糙度随切削力的变化情况
图 15  弹性回复高度对表面粗糙度的影响
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