面向多质量特性一体化控制高速钢丝锥制造理论与工艺研究

With the rapid development of science and technology,the users' demand for cutting tools become more and more increasingly.The features which measure the quality level of the cutting tool are many,but users concerned about only the three quality characteristics mostly ,they are precision , reliability and precision life.Since the domestic products has many deficiencies when compared to the foreign products, the three quality characteristics has become the key factors that constraints the enhance of cutting tool's technical level and competitiveness .The manufacturing process exert a serious influence on the quality of the cutting tool,but these days,the research of the relationship between the manufacturing process and quality is not enough, and through control the process to guarantee the quality of the product is still lack of a set of system of theories and methods. This thesis focus on improve the HSS tap's precision ,accuracy life and reliability, based on the research of cryogenic treatment technology and blade strengthening technology,systematically research of the quality assurance principle of the HSS tap manufacturing process,establish a systematic model of the tap's manufacturing process,explores an "integrated" collaborative control mechanism which can comprehensive guarantee the key quality characteristics of the HSS taps.A set of structured modeling technology of guaranteeing the quality of the HSS taps' manufacturing process are proposed, and provide a theoretical and technical support which in order to improve the quality of China 's high-end CNC tool .

随着科技的飞速发展，用户对切削刀具的要求越来越高，在衡量切削刀具质量水平的诸多特性中，用户最关注的是精度、精度寿命和可靠性三个质量特性。由于与国外产品的差距太大，这三个质量特性已成为制约我国切削刀具技术水平和竞争力提升的关键要素。切削刀具制造过程对质量的影响很大，但目前对制造工艺和质量的关系研究还很不够，对通过控制工艺过程保证产品质量还缺乏一套系统的理论和方法。本项目以高速钢丝锥为研究对象，以高速钢丝锥制造工艺设计为主线，以综合提高高速钢丝锥精度、精度寿命和可靠性三个关键质量特性为目标，以深冷处理技术和刃口强化技术研究为基础，系统研究高速钢丝锥制造过程的质量保证原理，建立高速钢丝锥制造过程的系统化模型，探索综合保证高速钢丝锥多关键质量特性的"一体化"协同控制机制，提出一套保障高速钢丝锥制造过程质量的结构化建模技术、求解算法和工艺保障方法，为提高我国高档数控刀具质量提供理论和技术支撑。

项目针对国产高速钢丝锥在精度、精度寿命和可靠性三个关键质量特性落后于国外进口丝锥的问题，系统研究了保证高速钢丝锥多关键质量特性一体化控制工艺、理论和设备，实现了丝锥精度、精度寿命和可靠性三个关键质量特性的综合调控，为提高我国高档数控刀具质量提供理论和技术支撑。主要研究内容和取得的重要结果、关键数据如下：（1）高速钢深冷处理技术研究。研究了深冷处理对W9、W6和EM35三种高速钢硬度和耐磨性的影响规律，结论是深冷处理的高速钢硬度有所提高，而耐磨性有大幅度提高，主要原因是有细小碳化物析出和碳化物的细化，以及残余奥氏体的转化；研究了深冷与回火位置，深冷温度、升降温速率、保温时间、回火温度、奥氏体化温度和深冷处理次数，对W9、W6两种高速钢材料硬度、红硬性、冲击韧性、残余应力和耐磨性等材料性能的影响规律；建立了马氏体转化过程中析出碳化物临界尺寸计算模型，从理论上证明了析出碳化物的临界尺寸。（2）刃口强化技术研究。研制了丝锥刃口电解强化试验平台，研究了W9和W6高速钢丝锥刃口强化理论与工艺，基于金属切削软件Advantedge，建立了高速钢丝锥加工H13和TC4的数学力学模型。（3）高速钢丝锥制造工艺研究。研究了深冷处理工艺和刃口强化工艺对高速钢丝锥精度、精度寿命和可靠性三大关键质量特性的影响规律，制定了新的高速钢丝锥制造工艺，淬火-深冷处理-回火-磨制螺纹-刃口强化-清洗-深冷处理。（4）丝锥制造质量特性控制与评价模型研究。建立了质量特性传递模型实现了丝锥制造的多质量特性一体化控制；建立了基于质量功能展开(QFD)的丝锥质量评价指标体系；建立了丝锥制造质量的多尺度评价指标体系。（5）切削试验研究。H13切削试验，精度寿命最大可提高约4.67倍，可靠性寿命t_0.95由0.0550提高到0.7918。钛合金TC4切削试验，精度寿命最大可提高约2.26倍。复合材料PA66尼龙板切削实验，精度寿命可提高约3.5倍。