强化刃口大切宽高速精密硬切削加工性能及刀具健壮性设计研究

Focusing on the urgent demand on machining efficiency improvement and controllable surface quality, this project proposes the machining-performance-controllable process of high-speed precision hard machining process with reinforced cutting edge and large cut width. The materials removal mechanism under adiabatic shear of high-speed precision hard machining process with reinforced cutting edge and large cut width will be studied. The mapping rules between the 3D shape of cutting edge and the cutting force and cutting heat will be built, and the microscopic structure evolution process and failure mechanism of the cutting edge will be revealed. To provide a quantitative reference for the application of high-speed precision hard cutting, the cutting performance predicting and evaluation method will be proposed for high-speed precision hard machining with reinforced cutting edge and large cut width. To promote machining performance of the tools and the performance stability under dynamic multivariate environment, the robust design method for high-speed hard machining tools with large cut width and cutting edge strengthening will be presented. This project can provide theoretical basis and practical tool technology of high-efficiency precision machining for high-speed hard machining, which has important theoretical significance and industrial value to the application of high-efficiency and high-performance machining technology for difficult-to-cut materials in equipment manufacturing industries.

本项目针对高效高性能硬切削技术的加工效率提升和表面质量可控的迫切需求，提出切削性能可控的刃口强化大切宽高速精密硬切削加工工艺。研究刃口强化大切宽高速精密硬切削绝热剪切行为下的材料去除机理；建立刃口三维形态与切削热和切削力的映射关系，揭示热力耦合作用下刀具刃口刃形微观组织结构演变过程和失效机制；研究刃口强化大切宽高速精密硬切削加工性能预测技术及其评价方法，为高速精密硬切削的实际应用提供可量化的参考；提出高速硬切削大切宽刀具及其刃口强化健壮性设计方法，提高刀具的切削性能和动态多变环境下的性能稳定性。本项目可为高速硬切削提供高效精密加工工艺的理论基础和实用化的刀具技术，对推进高效高性能难加工材料切削加工技术在装备制造行业的应用具有重要的理论意义和实用价值。

高效高性能刀具是高效切削、硬切削和绿色切削等先进切削工艺在生产中应用的重要保证。本项目针对高效高性能硬切削技术的加工效率提升和表面质量可控的迫切需求，以强化刃PCBN刀具设计及其切削加工性能为研究对象，开展了强化刃刀具设计制造、大切宽硬切削加工材料去除机理、刃口刃形保持性及加工表面质量等方面研究。提出了正弦和余弦等空间曲线强化刃PCBN刀具设计制造及检测方法，进行了强化刃PCBN刀具硬切削热力学特性研究，定量分析了切削力热沿切削刃的分布及其对切削刃的作用，获得了强化刃PCBN刀具切屑流动及形成机制。分析了强化刃刀具磨损形态的演变过程，阐明了切屑流动、热力载荷对刀具磨损的影响作用机制，揭示了强化刃刀具的磨损机理。提出了切削性能表征参数，获得了刃口形态和切削条件对加工表面三维形貌、加工表层微观结构特征和显微硬度影响规律。提出了响应曲面和有限元相结合的刃口强化健壮性设计方法，实现了双斜壁余弦强化刃刀具结构参数的优选，采用三维精密激光雕刻和喷砂处理相结合的方法，完成了所设计刀具微细结构制备，在此基础上还进行了双斜壁强化刃PCBN刀具切削性能验证和基于改进遗传算法的多目标综合优化。本项目所形成的强化刃刀具的设计制造理论和高效精密硬切削加工工艺对推进高硬难加工材料高效高性能切削加工技术在装备制造行业的应用具有重要的理论意义和实用价值。