目的 探究增减材复合制造不锈钢件过程中增材余温对减材加工过程中刀具磨损及表面粗糙度的影响,在干式切削条件下选择合适的增材余温进行减材加工,以实现对加工表面质量的控制,从而延长增减材复合制造不锈钢件的使用寿命,并提升其服役性能。方法 针对定向能量沉积不锈钢316L件,建立一种基于修正Johnson-Cook本构方程的本构模型,并通过二次开发建立切削仿真模型,通过应力-应变曲线和切削力验证了模型的准确性。基于有限元切削仿真,模拟切削过程中增材余温引起的工件温度升高对刀具表面温度及加工表面流动应力的影响。结合切削试验,对切削性能及加工表面质量进行分析。结果 通过切削仿真和实验可以观察到工件温度在20~400 ℃范围内,随着工件温度升高,切削力和加工表面流动应力逐渐降低,切削比能逐渐降低。当温度在260~400 ℃范围内时,温度过高导致刀具磨损加剧,刀具磨损量增大,表面质量下降,刀具磨损对表面质量的影响较大。结论 在增减材复合制造过程中,选取合适的增材余温能够在降低刀具磨损的同时,降低切削比能,减少能量消耗,提高加工表面的质量。
Abstract
In the hybrid additive-subtractive manufacturing of 316L stainless steel, only dry machining can be adopted. The residual heat generated by additive manufacturing affects the surface quality during subsequent subtractive machining, which in turn deteriorates the service life and performance of hybrid-manufactured components. Investigating the effects of residual heat from additive processes on cutting performance and surface quality helps reduce tool wear, improve machined surface quality, and ultimately enhance the service life and operational performance of parts produced via hybrid additive-subtractive manufacturing.
This study adopts a combined simulation and experimental approach for analysis. A modified Johnson-Cook (JC) constitutive equation is applied in the cutting simulation model, which is integrated into the finite element model via secondary development. Combined with experimental results, the effects of rising workpiece temperature on tool surface temperature and tool wear during machining are analyzed, along with the post-machining surface flow stress. Based on variations in workpiece temperature, the evolution laws of cutting force and specific cutting energy after single-pass and multi-pass machining are investigated. Experimental results reveal that for 316L stainless steel fabricated via laser directed energy deposition (LDED), the stress-strain curves obtained from Split Hopkinson Pressure Bar tests under dynamic compression gradually decline with the increase of temperature. The modified Johnson-Cook (JC) constitutive equation established based on the material's stress-strain responses at elevated temperatures and high strain rates can accurately predict the evolution of mechanical properties during dynamic compression. The reliability of the cutting simulation model is further verified by the variation of cutting forces. Both simulation and experimental results indicate that within the workpiece temperature range of 20-400 ℃, the rising temperature softens the workpiece and reduces its yield stress. Meanwhile, temperature elevation facilitates dislocation slip during the cutting of LDED-316L. Consequently, the cutting force and machined surface flow stress decrease progressively along with the rising workpiece temperature, and the specific cutting energy also presents a downward trend. At 220 ℃, the surface roughness is reduced by 68.93% compared with that at 20 ℃. When the temperature rises to 260-400 ℃, excessive heat drastically aggravates adhesive wear and diffusion wear of the cutting tool, leading to increased tool loss and risen surface roughness. Specifically, the surface roughness at 400 ℃ increases by 26.65% relative to the value at 220 ℃. It is demonstrated that the relationship between workpiece temperature and surface quality is not simply linear, and tool wear exerts a more prominent effect on the machined surface quality during cutting.
In hybrid additive-subtractive manufacturing, selecting an appropriate residual temperature from the additive process for subtractive machining under dry cutting conditions can not only reduce the cutting force and specific cutting energy, but also mitigate tool wear and improve machined surface quality.
关键词
增减材复合制造 /
不锈钢316L /
增材余温 /
刀具磨损 /
表面质量
Key words
hybrid additive-subtractive manufacturing /
316L stainless steel /
residual temperature from additive manufacturing /
tool wear /
surface quality
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基金
黑龙江省重点研发（2024ZX05B04）; 国家自然科学基金（52475441）
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