目的 为适应极端环境交变载荷冲击的复杂服役环境,需充分发掘20CrMnTi改性制造潜力,有必要开发新型抗疲劳性形协同制造方法,以实现多周期服役下长耐久性的工程价值。方法 提出一种基于加工动态热力耦合效应的磨削渗碳强化表面抗疲劳制造方法,建立考虑材料流动特性的磨削渗碳强化表面材料创成模型。混合碳粉和淀粉水溶液结合模具制备工件表面预置碳层,对20CrMnTi工件预磨削以保持较高的平面度,将脱水后的碳层置于工件表面,对工件表面材料进行大切深磨削以充分利用加工中的热力耦合效应以及砂轮高频次冲击微锻效应,实现加工表面的性形协同抗疲劳制造。同时,基于加工砂轮表面磨粒运动学规律与被加工材料冷作硬化性质,探明加工表面材料渗碳强化改性创成机制。结果 磨削渗碳强化加工表面磨削力可一定程度降低,这是由于材料流动特性降低,加工区域表面材料更容易过早发生断裂,强热力耦合作用下的渗碳强化加工表面粗糙度为0.97 μm,而较小加工参数下加工颤振所致的表面粗糙度为5.7 μm,且硬化后的硬度可达基体硬度的3.5倍,所获得的最大残余压应力为260 MPa。结论 该研究阐明了所提工艺方法的性形协同创成机制,可实现低碳合金钢表面的高性能制造,为极端环境关键表面性形协同制造提供理论与工艺价值。
Abstract
20CrMnTi is a kind of low-carbon alloy steel material with outstanding performance in the engineering field. To adapt to the complex service environment with the impact of alternating loads in extreme environments, it is necessary to fully explore the potential of 20CrMnTi modification and manufacturing, and develop a new anti-fatigue shape-performance collaborative manufacturing method to achieve the engineering value of long durability under multi-cycle service. A surface anti-fatigue manufacturing method of grinding and carburizing strengthening based on the dynamic thermomechanical coupling effect during machining was proposed, and a surface material generation model of grinding and carburizing strengthening considering the material flow characteristics was established. A preset carbon layer was prepared on the workpiece surface by mixing carbon powder and starch aqueous solution and mold. And the carbon layer was placed in a muffle furnace, and then dried and dehydrated at low heating temperature. The 20CrMnTi workpiece was pre-ground to maintain a relatively high flatness. The dehydrated carbon layer was placed on the workpiece surface, and the surface material of the workpiece was subject to deep grinding to fully utilize the thermomechanical coupling effect during machining and the high-frequency impact micro-forging effect of the grinding wheel, realizing the shape-performance collaborative anti-fatigue manufacturing of the machined surface. Meanwhile, based on the kinematics law of the abrasive grains on the grinding wheel surface during machining and the cold working hardening property of the machined material, the generation mechanism of carburizing strengthening modification of the machined surface material was explored. The grinding force on the surface processed by grinding and carburizing strengthening could be reduced to a certain extent. Moreover, it was found that the ductile removal of the surface material strengthened by grinding and carburizing was weakened, while the brittle removal of the material in the machining area was enhanced. This was because the material flow characteristics were reduced and the surface material in the machining area was more likely to break prematurely. The surface roughness of the carburizing strengthening processed surface under the strong thermomechanical coupling effect was 0.97 μm, while the surface roughness caused by machining chatter under smaller machining parameters was 5.7 μm. Moreover, the hardness after hardening could reach 3.5 times that of the substrate hardness, and the maximum residual compressive stress obtained was 260 MPa. By utilizing the thermomechanical coupling effect in the abrasive grain processing process, solid-state carburizing strengthening processing was carried out on the preset carbon layer on the surface. After the solid-state carbon source was activated into free carbon atoms, it directly changed the microscopic properties of the material and influenced the surface generation process. This dynamic generation process was jointly determined by the abrasive grains in high-speed motion, the thermomechanical coupling effect during machining, and the changing and moving laws of phase change materials. This study clarifies the shape-performance collaborative generation mechanism of the proposed process method, which can realize high-performance manufacturing on the surface of low-carbon alloy steel and provide theoretical and technological value for the shape-performance collaborative manufacturing of key surfaces in extreme environments.
关键词
20CrMnTi /
磨削渗碳强化 /
表面创成 /
材料流动
Key words
20CrMnTi /
grinding carburization strengthening /
surface generation /
material fluent
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基金
新疆维吾尔自治区自然科学基金面上项目（202501A64）; 新疆工程学院绿色选冶与材料加工科研创新团队资助; 新疆维吾尔自治区重点研发计划项目（2022B01036）
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