目的 解决钛合金切削时引发的刀具磨损过快和生产效率降低的难题。方法 利用飞秒激光设备将具有各向异性的特斯拉阀微织构结构引入YG8N硬质合金刀具的前刀面中,并对具有正向与反向结构的微织构刀具切削TC4钛合金的性能和加工特征进行分析研究。通过将切削试验与Johnson-Cook本构模型仿真相结合,分析微织构形貌特征对刀具切削力和切削温度的影响,同时探究切削温度对切削液黏度的影响,通过SEM观察刀具前刀面磨损和切屑的微观形貌。结果 随切削温度的升高切削液的黏度不断降低,同步切削液进入微织构底部的概率不断加大,而通过对微织构底部的元素组成分析,结果证实切削液能有效进入微织构中。在300 mm/s低速切削时,微织构刀具刀尖温度及切削力均低于无织构刀具,刀具前刀面黏附物明显减少,切削性能得到显著提升;在1 000 mm/s高速切削下,正向微织构刀具切削力比无织构刀具降低了19.4%,刀尖处的温度降低了29.4%,同时与低速切削工况相比也展现出更优异的切削性能。结论 特斯拉阀微织构通过改变刀具表面的切屑流动路径,减小刀具与切屑的接触面积,进而有效降低切削力、降低刀尖处的切削温度,同时减少了前刀面的黏附物和氧化层,有效减缓了刀具表面崩刃和黏结磨损现象,显著降低了摩擦系数与切削磨损,延长了刀具的使用寿命。
Abstract
Titanium alloys are widely used in aerospace, biomedical, and automotive industries due to their excellent strength-to-weight ratio and corrosion resistance. However, they are also known as typical difficult-to-machine materials, primarily because of issues such as rapid tool wear and low machining efficiency during cutting. The work aims to mitigate these challenges by enhancing the cutting performance and tool life during titanium alloy machining based on the principles of biomimetic structures and asymmetric fluid control. Through femtosecond laser fabrication, anisotropic micro-textures inspired by Tesla valve geometries were precisely engineered onto the rake face of YG8N cemented carbide turning tools. These micro-textures possessed unidirectional flow-guiding capabilities, which were expected to regulate chip flow direction and cutting fluid infiltration pathways during the machining process. Two texture orientations (forward and reverse) were designed to investigate the influence of texture alignment on cutting performance. In the experimental phase, comparative cutting tests were conducted on TC4 titanium alloy under two typical cutting conditions: low speed (300 mm/s) and high speed (1 000 mm/s). The effects of the micro-textures on cutting force, tool temperature, cutting fluid lubrication efficiency, and material adhesion on the rake face were systematically evaluated. Meanwhile, finite element simulations based on the Johnson-Cook constitutive model were employed to simulate the influence of the micro-textures on the thermal and stress fields in the cutting zone, thereby verifying their effectiveness in reducing friction and temperature under high-temperature and high-load conditions. To further elucidate the wear mechanisms of the cutting tools and the microstructural evolution at the tool-chip interface, scanning electron microscopy (SEM) combined with energy-dispersive spectroscopy (EDS) was used to analyze the microstructure and elemental distribution of the rake face and generated chips. Observations focused on identifying bonding wear, oxide film formation, and material transfer phenomena. The cutting fluid's viscosity was found to decrease progressively with the increase of the temperature, which could influence its ability to penetrate and lubricate the microtextured features. EDS analysis confirmed that the cutting fluid successfully infiltrated the bottom regions of the micro-textures.
At a low cutting speed of 300 mm/s, tools with micro-textures exhibited significantly better performance compared with non-textured tools. Specifically, the textured tools showed lower cutting forces and reduced tool tip temperatures. The adhesion of workpiece material on the rake face was also markedly reduced, indicating improved anti-adhesion and anti-wear characteristics. Under high-speed cutting conditions (1 000 mm/s), the forward Tesla valve micro-texture demonstrated even more pronounced benefits. Compared with the non-textured tool, it achieved a 19.4% reduction in cutting force and a 29.4% decrease in tool tip temperature, showcasing superior thermal and mechanical performance. The Tesla valve-inspired anisotropic micro-textures enhanced cutting performance by effectively guiding the flow of chips across the tool surface, thereby altering the chip-tool contact conditions. This led to a reduction in the effective contact area, which in turn decreased cutting forces and tool-chip interface temperatures. The improved lubrication and cooling effects helped to minimize adhesion, oxidation layers, and edge chipping, while also mitigating bonding wear. As a result, the micro-textures significantly reduced the coefficient of friction and cutting-induced wear, ultimately extending the tool's service life.
关键词
特斯拉阀微织构 /
刀具磨损 /
切削温度 /
切削形貌
Key words
Tesla valve micro-texture /
tool wear /
cut temperature /
chip morphology
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基金
山东省自然科学基金（ZR2022ME081）; 山东省重点研发计划（2019GNC106102）
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