基于Deform-3D的Inconel 718镍基合金的车削仿真

Inconel 718镍基高温合金的力学、抗氧化、抗热变形的性能好,但是加工性能差,材料塑性大、导热系数低、加工硬化严重等问题制约了镍基高温合金的广泛使用.文中运用有限元软件分析和研究材料的切削性能、刀具选择以及切削参数等问题,对解决镍基高温合金难加工的现状提供了参考价值.     

Inconel 718镍基高温合金车削切削力和切削温度分析

为探究切削参数对难加工材料Inconel 718镍基高温合金切削力和切削温度的影响规律,基于田口法对Inconel 718材料进行正交切削仿真试验,采用单因素分析方法、灰关联度分析方法对比分析切削三要素对切削力、切削温度的影响,研究结果为Inconel 718镍基高温合金高效切削加工提供理论支撑。     

精密切削加工Inconel718镍基高温合金的涂层硬质合金刀具磨损试验研究

Inconel718镍基高温合金适用于高温高压、高频应力应变及腐蚀环境,被广泛应用于核电、航天、航空等领域.针对核级Inconel718镍基高温合金开展精密切削加工试验,研究不同工艺参数对涂层硬质合金刀具磨损的影响.结果 表明:涂层硬质合金刀具前后刀面极易发生磨损,出现月牙洼磨损、沟槽磨损以及崩刃;车削三要素中进给量对后刀面磨损量VB的影响最为明显,随着进给量的增大,后刀面磨损量VB逐渐减小.     

基于DEFORM-3D的镍基合金钢的车削加工仿真

运用IN718镍基高温合金流动应力模型进行数值模拟,考查了IN718镍基高温合金车削过程中工艺参数对切削性能和刀具的影响。结果表明:在各因素中,对切削温度而言,切削速度影响最大,进给量次之,背吃刀量影响最小;对切削力而言,切削速度影响最小,背吃刀量影响最大。换热系数对工件和刀具的最高温度和平均切削力影响不大,但工件和刀具的平均温度随着换热系数的增大而减小。研究结论有助于优化IN718镍基高温合金车削过程中工艺参数的选择与优化。     

用于加工Inconel718的切削刀具发展现状

镍基高温合金Inconel718具有熔点高、热传导率低、加工硬化现象严重的特点,被认为是最难加工的金属材料之一。近年来,随着航空航天、能源动力技术的飞速发展,Inconel718高温合金的应用越来越多,其高速、高效切削的加工需求也日益扩张,其切削工艺的制定、尤其是切削刀具的选择越来越重要。本文综述了常用于加工In-conel718的刀具(高速钢、硬质合金、陶瓷、立方氮化硼)及其涂层刀具的加工性能,分析了不同涂层对于刀具寿命和工件表面质量的影响,对硬质合金刀具和陶瓷刀具作了详尽的对比分析。最后,对高速钢、陶瓷、硬质合金和立方氮化硼刀具切削Inconel718的应用情况进行了总结,给出了Inconel718高温合金切削加工刀具选择的有益参考。     

镍基高温合金加工研究

简要介绍了镍基高温合金的物理性能和加工性能;进而介绍了国内外镍基高温合金切削加工的研究成果,主要分析重点集中在刀具材料的选择及切削性能的研究等方面;最后介绍了Inconel617切削加工性能和小孔加工工艺。     

镍基718材料表面润湿性对耐磨和耐腐蚀性能的影响

针对镍基高温合金Inconel 718材料,探究铣削加工参数与表面润湿特性的关系,研究不同液体介质(水、人工海水、32号润滑油)接触角变化对表面摩擦磨损及耐腐蚀性能的影响。利用正交试验法研究铣削参数(切削速度V_s、每齿进给量f_z以及切削深度a_p)与表面润湿性的关系,利用单因素试验研究接触角变化对摩擦系数f和腐蚀速率的影响。对于镍基高温合金Inconel 718材料表面,水的接触角θ、每齿进给量f_z对其影响最大,切削深度a_p次之,铣削速度V_s最小,且在V_s=60m/min、f_z=0.05mm/r、a_p=0.6mm时接触角最小;采用32号油润滑时,分别观察接触角θ为9°、12°、16°、19°、21°时摩擦系数的变化;随着θ的增大,摩擦系数f在0.08～0.20之间逐渐增加,增大趋势明显;对于水润滑,摩擦系数f随接触角θ增加,并在0.24～0.27之间变化,增大的趋势很微弱;对于长期工作于海水中的镍基高温合金Inconel 718材料表面,接触角θ从61°增大到79°时,相同时间内腐蚀量从0.65%下降为0.45%,耐腐蚀性变好。对于镍基高温合金Inconel 718材料表面的铣削加工,为获得较好的润湿性能,应重点关注每齿进给量f_z和切削深度a_p;为提高Inconel 718材料表面的摩擦性能,应尽量减小表面对润滑剂的接触角;提高对腐蚀性介质的疏水性则可以有效改善Inconel 718材料表面的耐腐蚀性能。     

基于ABAQUS和Python的镍基高温合金Inconel718的车削仿真

为了准确地对镍基高温合金Inconel 718的车削过程进行仿真,并找出影响车削力的主要可控变量,应用ABAQUS有限元软件较精确地对镍基高温合金Inconel 718的车削加工过程进行仿真,模拟车削加工过程中背吃刀量、切削线速度、进给量等可控因素对刀具主切削力、进给抗力、切深抗力的影响。调用Python中的Pandas库读取正交试验表中的数据并算出各因素对刀具受力的相关系数矩阵,通过对比相关系数得出各主要因素对刀具受力影响程度的大小,验证了该材料车削仿真的准确性。     

镍基高温合金Inconel718在不同冷却润滑条件下的切削仿真研究

为探究冷却润滑条件对难加工材料镍基高温合金Inconel 718切削加工质量影响规律,基于Advantedge有限元软件,采用三种不同的冷却润滑方式,对Inconel 718材料进行干式切削、浇注式切削、低温冷风微量润滑切削仿真,对比分析不同冷却及润滑条件对切削力、切削温度、切屑形态、残余应力变化的影响规律。     

GH4169镍基高温合金的高温低周疲劳性能

对国产GH4169镍基高温合金进行了总应变控制的高温低周疲劳试验,研究了其疲劳性能,分析了断口形貌。结果表明:试验合金具有较好的高温低周疲劳性能,与进口Inconel 718镍基合金的相近,但在较低的总应变范围下比Inconel 718合金的疲劳寿命要低;该合金在不同总应变范围下都表现出明显的循环软化行为;合金试样的疲劳断口呈多裂纹源性,疲劳源数量随总应变范围的降低和疲劳寿命的延长而减少;疲劳裂纹都萌生于表面,穿晶扩展到一定径向深度时,会出现沿晶扩展特征。     

Evaluation of machining performance in cryogenic machining of Inconel 718 and comparison with dry and MQL machining

There has been significant work on establishing relationships between machining performance and the cutting parameters for various work materials. Recent trends in machining research show that major efforts are being made to understand the impact of various cooling/lubrication methods on machining performance and surface integrity characteristics, all aimed at improving process and product performance. This study presents the experimental results of cryogenic machining of Inconel 718, a high-temperature aerospace alloy, and comparison of its performance in dry and minimum quantity lubrication machining. Experimental data on force components, progressive tool wear parameters such as flank wear, notch wear, crater wear, cutting temperature, chip morphology, and surface roughness/topography of machined samples are presented. New findings show that cryogenic machining is a promising research direction for machining of high-temperature aerospace alloy, Inconel 718, as it offers improved machining performance in terms of reduced tool wear, temperature, and improved surface quality. It was also found that the number of nozzles in cryogenic machining plays a vital role in controlling cutting forces and power consumption in cryogenic machining of Inconel 718.     

Development of a pressurized internal cooling milling cutter and its machining performance assessment

In view of the serious problem of milling heat in milling nickel-based superalloys Inconel 718, this paper investigates the heat transfer performance of internal cooling in end milling Inconel 718, and the superiority of internal cooling milling cutter's heat exchange ability during processing is explored. The flow field characteristics of cutting fluid and milling temperature are studied by Computational Fluid Dynamics (CFD) and Finite Element Method (FEM). Compared with external flood cooling, the principle of internal cooling with excellent heat transfer performance is explained and the influence of coolant pressure on lubrication performance is analyzed. Experiments for end milling of Inconel 718 under different cutting speeds and cooling conditions have been carried out. The results indicate that the simulated and measured temperatures showed an acceptable agreement. The internal cooling has better heat transfer performance compared with flood cooling. With the increase of coolant pressure, the heat exchange efficiency is gradually enhanced. When the coolant pressure rises from 2 bar to 10 bar, the milling temperature at the measured point inside the workpiece reduces by 27.55 °C, the surface roughness reduces by 12.0%, the surface residual compressive stress increases by 68.37 MPa and better surface morphology is obtained. Besides, in the experimental range, with the increase of cutting speed, milling temperature increased, the pile-up effect on the sides of scratching was weakened and better machined surface integrity was found.     

球头铣刀高速切削Inconel 718的刀具磨损研究

为了实现航空高温合金的高速高效加工,通过对Inconel718的铣削试验,分析了涂层球头铣刀切削高温合金时的加工性能。试验结果表明,乳化液在90m/min的切削速度下仍然具有较好的冷却润滑作用。通过对TiAlN涂层和TiAlN+Al2O3涂层刀具的对比试验,证明TiAlN涂层具有优异的耐磨性,可显著提高加工高温合金时的刀具寿命。     

Study of surface quality in machining nickel-based alloy Inconel 718

In machining operation, the surface quality is one of the most important requirements for many workpieces. Because of the special physical and chemical properties, good-machined surface quality becomes a key issue to solve in machining Inconel 718. In this paper, PVD-TiAlN-coated carbide tools were used to turn Inconel 718. Based on observing the tool wear and machined surface morphology, the main factors affecting surface quality at different cutting speeds were analyzed. The optimal cutting temperature was calculated, according to the above analysis and Archard adhesion wear model, and further cutting parameters optimization was conducted, on the basis of the proposed optimal cutting temperature. The optimized cutting parameters based on optimal cutting temperature can be considered to improve surface quality.     

Effect of cutting parameters on the degree of work hardening and tool life during high-speed machining of Inconel 718

The use of superalloy Inconel 718 is increasing in most of the sophisticated applications like aircraft engines, industrial gas turbines, rocket engines, space vehicles, submarines, etc. Hence, in-depth understanding of this material helps to determine the ability of this material to withstand severe conditions of stress, temperature, corrosion, and controls its longevity and reliability. In the present work, an attempt has been made to study the relationship of degree of work hardening and tool life as a function of cutting parameters like cutting speed, feed, depth of cut, untreated tungsten carbide and postcryogenic-treated tool. Work hardening and tool life are the major factors which need to be controlled/improved to enhance the machinability characteristics of superalloy Inconel 718. A significant performance in tool life was observed due to cryogenic treatment given to tungsten carbide tool. Moreover, it was observed that optimized cutting parameters not only minimized/controlled work hardening characteristics but also improved tool life while high-speed machining of Inconel 718.     

高速车削Inconel 718切削力的试验研究

为了研究高速切削Inconel 718的切削力经验公式和各切削参数对切削力的影响显著程度,应用涂层硬质合金刀具对Inconel 718进行了正交车削试验,得到了硬质合金刀具车削Inconel 718的切削力经验公式。分析结果表明:对切削力影响最大的因素是进给量,切削深度和切削速度对试验结果的影响依次减弱。用涂层硬质合金刀具KC5510精车Inconel 718时,采用小进给量、小切削深度、高切削速度可以得到小的切削力,取得良好的切削效果。     

Chip Formation Mechanism of Inconel 718:A Review of Models and Approaches

Inconel 718,a nickel,chrome and iron alloy,has special advantages,such as high-temperature strength,thermal resistance and corrosion resistance,which facilitate wide usage in the aerospace industry,especially in the hot sec-tions of gas turbine engines.However,machining this alloy is correlated closely with the material's inherent properties such as excellent combination of strength,hardness and toughness,low thermal conductivity and the tendency to adhere to cutting tools.This nickel alloy also contains inclusions of hard abrasive carbide particles that lead to work-hardening of the workpiece material and thus abrasive wear of the cutting tool.That is,the machining of Inconel 718 is always influenced by high mechanical and thermal loads.This article reviews the chip formation mechanism of Inconel 718.One of the main characteristics in machining of Inconel 718 is that it will produce serrated or segmented chips in a wide range of cutting speeds and feeds.Existing studies show that the chip serration or segmentation by shear localization affects the machined surface integrity,and also contributes to the chip's evacuation and the auto-mation of machining operations.Thus,research conclusion indicates that the serrated or segmented chip phenom-enon is desirable in reducing the level of cutting force,and detailed analysis of models and approaches to understand the chip formation mechanism of Inconel 718 is vital for machining this alloy effectively and efficiently.Therefore,this article presents some summaries on the models and approaches on the chip formation in machining of Inconel 718.     

镍基合金Inconel718可切削加工性的试验研究

Inconel718是一种高强度耐热镍基合金,具有优良的高温强度、高温硬度和耐蚀性,在高温条件下能长期工作,已被广泛地应用于宇航工业、航空工业的涡轮发动机和相关零件的制造。分析Inconel718的机械性能、微观组织结构及其对切削加工性能的影响并进行了相关的试验验证,在试验数据的基础上,研究Inconel718中含碳量对切削过程中刀具磨损的影响。试验结果表明,Inconel718中含碳量在刀具后刀面磨损中起着非常重要的作用,Inconel718合金中含碳量越高,合金中所含的细微硬质夹杂物也越多,在切削过程中使刀具产生严重的后刀面磨粒磨损,从而降低材料的切削加工性。     

Development of a novel cubic boron nitride cutting tool with a textured flank face for high-speed machining of Inconel 718

Nickel-based superalloys such as Inconel 718 offer several advantages, including high-temperature strength and high corrosion resistance; this has led to a rapid increase in the demand for such materials, particularly in the aircraft industry. In contrast, these alloys are known to be among the most difficult-to-cut materials because of their mechanical and chemical properties, and tools used for this purpose have extremely short lifetimes. Recently, cubic boron nitride (CBN), which is the second hardest of all known materials, has received significant attention as a material for cutting tools and has already established itself in many fields of application. However, the performance of CBN tools is still insufficient for practical use, especially in the high-speed machining of Inconel 718. To overcome this problem, we first conducted orthogonal cutting experiments on Inconel 718 and performed cross-sectional observations of the CBN cutting tool in order to identify its wear mechanisms in continuous cutting operations under high-speed machining conditions (300 m/min). As a result, it was found that fatal tool failure occurs through crater and flank wear because of diffusion led by high cutting temperatures and subsequent chip adhesion to the tool flank face, accompanied by cutting edge chipping. Based on these results, a CBN cutting tool with a textured flank face was newly developed to improve the cutting tool life. Experimental: results showed that micro grooves generated on the flank face significantly suppressed the cutting edge chipping and remarkably extended the lifetime of the CBN tool during high-speed machining of Inconel 718.     

Experimental study of surface integrity and fatigue life in the face milling of inconel 718

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.