NOTCH WEAR OF MACHINING NICKEL BASED ALLOYS WITH CERAMIC TOOLS

ＮＯＴＣＨＷＥＡＲＯＦＭＡＣＨＩＮＩＮＧＮＩＣＫＥＬＢＡＳＥＤＡＬＬＯＹＳＷＩＴＨＣＥＲＡＭＩＣＴＯＯＬＳＮＯＴＣＨＷＥＡＲＯＦＭＡＣＨＩＮＩＮＧＮＩＣＫＥＬＢＡＳＥＤＡＬＬＯＹＳＷＩＴＨＣＥＲＡＭＩＣＴＯＯＬＳＨｅＮｉｎｇ；ＰａｎＬｉａｎｇｘｉａｎ...     

WORK PRINCIPLE AND CHARACTERISTIC ANALYSES OF HYDROSTATIC BEARING

Aiming at the new characteristic of water hydraulic system, a kind of hydrostatic bearing with a concentric gap damper is introduced. The lubricative film thickness of the hydrostatic bearing possesses inflexibility and the loading capacity is just determined by the geometrical dimension of the piston-slipper subassembly and has no relation with system pressure, viscosity and temperature of water and speed of rotor. Theoretical analyses and the verification of scheme done at the test rig show that the hydrostatic bearing with a concentric gap damper is especially fit for water hydraulic components.     

STUDY ON WEAR AND DESTRUCTION OF HOB IN GEAR HOBBING

The wear and destruction appearances of hobs are researched. The reasons of the wear and destruction of hobare analyzed. And the influence of the change of the bobbing force and the bobbing temperature on the wear and destruction of hob in gear bobbing is also analyzed. In gear bobbing, the main wear mechanisms are adhesion and ploughingwhen cutting the 20CrMnTi gear using W18Cr4V high-speed steel hob.     

PCBN刀具切削GCr15淬硬轴承钢的研究

通过切削实验，研究了PCBN刀具精密切削淬硬GCr15轴承钢时切削力的特征、锯齿切屑的形态和刀具的员特征，又从表面粗糙度、硬化层深度、亚表层的白层现象和残余应力的分布方面深入研究了PCBN刀具精密切削淬硬轴承钢的适应性，实验结果表明，PCBN刀具应用于GCr15轴承钢的精密切削是可行的。     

DISTRIBUTION OF Cu AND ITS EFFECT ON MICROSTRUCTURE OF Cu-BEARING STEEL

In order to investigate the distribution of Cu and its effect on the microstructure of Cu-bearing steel, a series of mild steels containing different contents of Cu are developed by vacuum electric arc furnace. These steels are annealed at 1 260℃, 1 100℃and 1 000℃respectively for one hour and followed by furnace cooling to room temperature to simulate the heat treatment before the rolling process. The results show that Cu did not obviously segregate in annealed steels. The scanning electron microscope (SEM) observation show that the main microstructures in Cu-bearing steel are ferrite and pearlite; The volume fraction of pearlite in steel increase with increasing Cu content. The grain size reduces with the decrease of annealing temperature. The results of energy dispersive X-ray analysis (EDXA) suggest that the Cu content in pearlite is higher than that in ferrite, which means that the microstructure-segregation of Cu exists. However, the cast specimens show that Cu content in MnS and S-rich phase is very high, and Cu changed the distribution of MnS in steel. In addition, the optimal Cu content in steel between 0.2%-0.4% and the optimal annealing temperature between 1 100-1 200℃are determined by the economical and practical principles.     

用PCBN刀具精密切削GCr15淬硬轴承钢

通过切削试验研究了PCBN刀具精密切削GCr15淬硬轴承钢时的切削力特征、切屑形态、刀具磨损特性等切削性能 ,并从表面粗糙度、硬化层深度、亚表层白层现象、残余应力分布等方面研究了PCBN刀具精密切削淬硬轴承钢的加工表面质量     

MEASURING AND MODELING OF THE MECHANICAL PROPERTIES OF COMPOSITE BEARING PAD MADE OF PLASTIC MATRIX AND FINE BRONZE ELASTIC SPRINGS

The viscoelastic properties of the normal PTFE plastic and strengthened PTFE plastic for bearing pad are measured. The mechanical properties of the composite material for bearing pad, which is made of the aforementioned plastics as matrix reinforced by fine bronze elastic springs, are modeled and relaxation modulus of the material are presented. The difference between these two kinds of PTFE is studied. The results show that the complex modulus of PTFE plastics for bearing pad is higher than that of normal PTFE plastics.     

FATIGUE LIFE PREDICTION THEORY OF COMPOSITE LAMINATES AND EXPERIMENTAL VERIFICATION

According to traditional phenomenological fatigue methodology and modem continuum damage mechanics theory, dual fatigue cumulative damage rules to predict fatigue damage formation and propagation lives of the notched composite laminates are presented. A 3-dimensional damage constitutive equation of anisotropic composites is also established. Damage strain energy release rate is interpreted as a driving force of the fatigue delamination damage propagation. A new damage evolution equation and a damage propagation σa-σm-N surface (stress amplitude-mean stress-life surface) are derived. Hence, using the method above, the fatigue life of composite components can be predicted. Finally, theoretically predicted results are compared with experimental data. It is found that the deviation of theoretic prediction from experimental results is about 22%.     

PCBN刀具和硬质合金刀具铣削GCr15的对比试验研究

在干式切削的条件下,采用单因素试验法,比较分析了PCBN刀具和硬质合金刀具铣削轴承钢GCr15的差异。结果表明:PCBN刀具在铣削过程中不产生积屑瘤,可获得更好的表面粗糙度,后刀面的磨损较小。     

PCBN刀具切削淬硬钢GCr15的磨损实验研究

以PCBN刀具切削淬硬轴承钢GCr15为实验对象，对干湿切削条件下的刀具磨损形式、磨损原因及刀具寿命进行了对比实验研究。实验结果表明：干湿切削磨损形式相似，但干切削时前刀面磨损面积较大；磨损机理主要为摩擦磨损、粘结剂磨损、扩散磨损和氧化磨损；湿切削比干切削的正常磨损时间稍长一些。     

CUTTING TEMPERATURE OF TEMPERING BEARING STEEL GCr15 CUT BY PCBN CUTTER

０　ＩＮＴＲＯＤＵＣＴＩＯＮＰＣＢＮ（Ｐｏｌｙｃｒｙｓｔａｌｌｉｎｅｃｕｂｉｃｂｏｒｏｎｎｉｔｒｉｄｅ）ｃｕｔｔｅｒｓｈａｖｅｂｅｅｎｕｓｅｄｉｎｍａｃｈｉｎｉｎｇｆｏｒｔｗｅｎｔｙｙｅａｒｓｓｉｎｃｅｔｈｅｙｗｅｒｅｓｕｃｃｅｓｓｆｕｌｌｙｄｅｖｅｌｏｐｅｄｉｎｔｈｅ１９７０’ｓ．Ｆｏｒｈａｖｉｎｇｇｏｏｄｃｕｔｔｉｎｇｐｒｏｐｅｒｔｉｅｓ,ｔｈｅｙｒｅｃｅｉｖｅｄｗｉｄｅｌｙａｔｔｅｎｔｉｏｎ．ＭａｎｙｆａｃｔｏｒｉｅｓｄｅｖｅｌｏｐｅｄｍａｎｙｋｉｎｄｓｏｆＰＣＢＮｐｒｏｄｕｃｔｓｗｈｉｃ…     

EFFECTS OF CUTTING SPEED WHEN TURNING AGE HARDENED INCONEL 718 WITH PCBN TOOLS OF BINDERLESS AND LOW-CBN GRADES

Application of polycrystalline cubic boron nitride (PCBN) tools as an alternative for ceramic and cemented carbide tools in machining superalloys has been frequently identified as a solution for enhancing process efficiency but only a limited number of studies has been done in this area. The current study explores the effect of the cutting speed, which was varied in a wide range (2–14 m/s), on machinability of age hardened Inconel 718 with PCBN tools. Performance of binderless PCBN grade and grade with low-cBN content was evaluated in terms of tool life, tool wear, cutting forces and surface quality. Chip formation and process dynamics were analyzed as well. It was found that low-cBN grade provided 70–90% better surface finish and tool life than the binderless at moderate speeds (5–8 m/s). Performance of both grades at low and high speed ranges was non-satisfactory due to notching and flaking respectively. At low cutting speed adhesive wear plays a major role while as the speed increases a chemical wear becomes dominant.     

PCBN刀具干切削淬硬轴承钢时磨损机理的研究

通过干切削淬硬GCr15轴承钢的PCBN刀具磨损试验 ,得出了后刀面刀具磨损曲线 ,结合扫描电镜对刀具的磨损形态进行了宏观和微观观察 ,研究了PCBN刀具的磨损特征及磨损机理 ,并对切屑形态与刀具磨损之间的关系进行了初步探讨     

GCr15钢超高周疲劳行为的实验研究

以GCr15钢为实验材料进行旋转弯曲超高周疲劳行为的实验研究.用光学显微镜和扫描电镜对试样疲劳断口进行观察,结果显示,疲劳断裂周次从106直到4×108,GCr15钢疲劳裂纹大多起源于试样内部,裂纹源一般为非金属夹杂物.从内部起裂的试样,疲劳寿命一般比从表面起裂试样的寿命长.文中从断裂力学和断裂物理的角度,对实验结果和疲劳机理进行分析.     

PCBN刀具的磨损机理和干切削GCr15时的磨损与寿命

研究了PCBN刀具的磨损机理和磨损形式。通过对干切削GCr15轴承钢时刀具的磨损形式及寿命进行试验研究 ,得出了工件硬度、切削速度对PCBN刀具磨损的影响规律以及工件硬度在临界硬度附近时刀具磨损速度最快的结论。加工两种硬度工件时的刀具寿命方程表明 ,切削速度对PCBN刀具寿命的影响小于对硬质合金及陶瓷刀具寿命的影响。     

高碳铬轴承钢的超长寿命疲劳行为的研究

使用砂漏型试样对高碳铬轴承钢的S-N曲线特性和破坏机理进行了研究。通过旋转弯曲疲劳试验获得的S-N曲线按照破坏模式的不同被划分为裂纹萌生位置不同的两组。一组叫做表面破坏模式的S-N曲线,它发生在高应力幅短寿命区,是由试样表面晶体滑移引起的。另一组叫做内部破坏模式的S-N曲线,它发生在低应力幅长寿命区,是由试样内部的非金属夹杂引起的。由于内部破坏模式的疲劳破坏发生在表面破坏模式的疲劳极限上下很宽的应力幅范围,因此,试验材料的S-N曲线的形状与通常报道的阶梯形状的S-N曲线的形状不同,它具有两条S-N曲线的特性。通过对断口上裂纹萌生位置的详细观察和裂纹萌生位置的初期尺寸参数的计算,阐述了内部破坏模式的破坏机理,提出了基于尺寸参数的超长寿命疲劳极限的推定方法。     

研磨加工层对高碳铬轴承钢超长寿命疲劳行为的影响

为了阐明磨石研磨加工层对高碳铬轴承钢JIS SUJ2超长寿命疲劳行为的影响,分别使用经砂纸研磨和电解研磨的砂漏形试样,在室温空气环境下进行旋转弯曲疲劳试验.砂纸研磨试样被除去部分磨石研磨层,电解研磨试样被除去了全部的磨石研磨层.结果表明,两种试样的S-N曲线由位于短寿命区的表面破坏模式和位于长寿命区的内部破坏模式的两条组成,表面破坏模式的S-N曲线受表面粗糙度和表面压缩残余应力的影响.内部破坏模式的S-N曲线不受表面条件的影响,是材料固有的特性.砂纸研磨试样表面破坏模式的疲劳极限最高,是电解研磨试样1.11倍和磨石研磨的1.20倍.表面压缩残余应力对表面破坏模式疲劳极限的影响可以用修正Goodman图表示.还讨论裂纹的萌生和扩展条件,推定超长寿命的疲劳极限.     

高速工具钢的超长寿命S-N曲线特征和内部裂纹萌生行为

为了研究高速工具钢超长寿命S-N曲线特征和内部裂纹萌生行为,使用沙漏形状试样在室温空气环境下进行旋转弯曲的疲劳试验。结果表明,材料的S-N曲线均由表面裂纹萌生型和内部裂纹萌生型组成。表面裂纹萌生型的S-N曲线位于高应力幅短寿命区,内部裂纹萌生型的S-N曲线位于低应力幅长寿命区。前者的S-N曲线向后者的转移几乎是连续的,回火温度对疲劳强度和寿命没有明显的影响。分别使用扫描电子显微镜、扫描探针显微镜和电子探针X射线微区分析仪对内部裂纹萌生位置和材料组织进行对比观察,在萌生内部裂纹的夹杂物周围存在一个颗粒区域,该区域内凸起的颗粒是组织中的球形碳化物。颗粒区是在内部裂纹扩展的应力强度因子门槛值范围以下形成的,对超长寿命疲劳起着重要的作用。     

GCr15钢不同回火态扭转流变硬化行为和组织强度研究

研究了ＧＣｒ１５钢淬火不同温度回火后扭转流变硬化行为、组织和强度的关系。研究表明，在双对数坐标上硬化曲线呈现多ｎ行为。在低于２５０℃回火，随回火温度降低，诸ｎ值增大的原因很多，但残余奥氏体及其塑变诱导相变强化效应在其中起着主要作用。在高温回火范围，随回火温度降低，诸ｎ值减小的原因与渗碳体质点间距，即位错运动平均自由程（ＭＦＰ）有关。尽管宏观扭转断口有正断和切断之分，但微观断口均为韧窝，这表明塑变和硬化在断裂过程中起着重要作用。据此，可借助τ（０．３）、γｋ和ｎｌ值的变化分析τｋ值随回火温度变化的规律。