淬硬超高强度钢45CrNiMoVA硬车削加工性研究

doi:10.12382/bgxb.2021.0757

摘要/Abstract

摘要：

为避免淬硬钢磨削工艺易引入残余拉应力以及大量使用切削液对环境造成严重污染的问题，采用硬车削代替磨削的加工方法。针对淬硬-回火45CrNiMoVA钢进行以车代磨工艺的研究，分析硬车削过程中的切削力、加工表面形貌、残余主应力及显微硬度。结果表明，切削力随切削深度和进给量的增大而增大，切削速度的改变对切削力的影响不大；硬车削后工件表面形貌一致性良好，表面粗糙度Ra值可达0.64 μm；残余主应力随进给量和切削深度的增大而减小，随切削速度的增大先减小后增大；最大残余主应力的方向角随切削速度与切削深度的增大在37°~ 45°范围内保持稳定，随进给量的增大在22°~ 45°范围内先增大后保持稳定；表面显微硬度随切削速度的增大而减小，硬车削后表面显微硬度提高了13%，硬化层深度约200 μm。

关键词: 45CrNiMoVA钢, 硬车削, 切削力, 表面形貌, 残余主应力, 显微硬度

Abstract:

In order to avoid tensile residual stress and heavy use of highly-polluting cutting fluid, in the grinding process of hardened steel, a hard turning process is proposed. The turning process is carried out for the quenched-tempered 45CrNiMoVA steel. The cutting forces during the process are recorded, and the surface morphology, residual principal stress, and microhardness of the machined surfaces are analyzed. The results show that the cutting forces increase with the cutting depth and feed rate. However, the change in cutting speed has little effect on the cutting force. The surface roughness Ra of the workpiece after hard turning can reach 0.64 μm. The consistency of surface morphologies is also satisfying. The residual principal stress decreases with the increase of the feed rate and the cutting depth. By comparison, the residual principal stress first decreases and then increases with the increase of the cutting speed. The direction angle of the maximum residual principal stress changes steadily within the range of 37°~45° with the increase of cutting speed and cutting depth. It first increases and then maintains stable within the range of 22°~45° with the increase of feed. The surface microhardness decreases with the increase of cutting speed, and the depth of hardened layer is about 200 μm.

Key words: 45CrNiMoVA steel, hard turning, cutting force, surface morphology, residual principal stress, microhardness

杜凯, 焦黎, 颜培, 余建杭, 王玉彬, 仇天阳, 王西彬. 淬硬超高强度钢45CrNiMoVA硬车削加工性研究[J]. 兵工学报, 2023, 44(3): 773-782.

DU Kai, JIAO Li, YAN Pei, YU Jianhang, WANG Yubin, QIU Tianyang, WANG Xibin. Study of the Hard Turning Processability of Hardened Ultra-high Strength Steel 45CrNiMoVA[J]. Acta Armamentarii, 2023, 44(3): 773-782.

图/表 25

表1 45CrNiMoVA化学成分含量

Table 1 Chemical composition of 45CrNiMoVA wt.%

C	Cr	Ni	Mo	V	Si	Mn
0.42~0.49	0.80~1.10	1.30~1.80	0.20~0.30	0.10~0.20	0.17~0.37	0.50~0.80

图1 45CrNiMoVA微观组织

Fig. 1 Microstructure of 45CrNiMoVA

表2 45CrNiMoVA材料的力学性能

Table 2 Mechanical parameters of 45CrNiMoVA

抗拉强度R_m/MPa	屈服强度R_p0.2/MPa	断后延伸率A / %	断面收缩率Z /%
2030	1635	13.5	52

图2 硬车削试验平台

Fig. 2 Test platform for hard turning

表3 硬车削单因素试验方案

Table 3 Single-factor hard-turning experiment parameters

序号	切削速度 v_c / (m·min^-1)	切削深度 a_p/mm	进给量f / (mm·r^-1)
1-1	120	0.10	0.03
1-2			0.06
1-3			0.09
1-4			0.12
2-1	120	0.05	0.09
2-2		0.10
2-3		0.15
2-4		0.20
3-1	100	0.10	0.09
3-2	120
3-3	140
3-4	160

图3 残余应力测试装置图

Fig. 3 Residual stress test device

图4 实测切削力信号图

Fig. 4 Measured cutting force signals

图5 进给量对切削力的影响曲线(vc=120 m/min，ap=0.10 mm)

Fig. 5 Influence of feed on cutting force (vc=120 m/min, ap=0.10 mm)

图6 切削深度对切削力的影响曲线(vc = 120 m/min，f = 0.09 mm/r)

Fig. 6 Influence of cutting depth on cutting force (vc = 120 m/min, f = 0.09 mm/r)

图7 刀具-工件切削接触区域示意图

Fig. 7 Schematic diagram of the tool-workpiece contact area

图8 切削速度对切削力的影响曲线(f = 0.09 mm/r，ap =0.10 mm)

Fig. 8 Influence of cutting speed on cutting force (f =0.09 mm/r, ap =0.10 mm)

图9 不同工艺参数下的表面形貌图(上为二维纹理图，下为三维形貌图)

Fig. 9 Surface topography of the specimens under different cutting process parameters(the above is a two-dimensional pattern map and the following is a three-dimensional morphology picture)

图10 进给量对表面粗糙度的影响曲线(vc = 120 m/min，ap = 0.10 mm)

Fig. 10 Influence of feed rate on surface roughness (vc = 120 m/min, ap = 0.10 mm)

图11 切削速度对表面粗糙度的影响曲线(f = 0.09 mm/r，ap = 0.10 mm)

Fig. 11 Influence of cutting speed on surface roughness (f = 0.09 mm/r, ap = 0.10 mm)

图12 切削深度对表面粗糙度的影响曲线(f = 0.09 mm/r，vc = 120 m/min)

Fig. 12 Influence of cutting depth on surface roughness (f = 0.09 mm/r, vc = 120 m/min)

图13 残余应力测试示意图

Fig. 13 Schematic diagram of residual stress test

图14 进给量对残余应力的影响曲线(vc = 120 m/min，ap = 0.10 mm)

Fig. 14 Influence of feed rate on residual stress (vc = 120 m/min, ap = 0.10 mm)

图15 切削深度对残余应力的影响曲线(vc = 120 m/min，f = 0.09 mm/r)

Fig. 15 Influence of cutting depth on residual stress (vc = 120 m/min, f = 0.09 mm/r)

图16 切削速度对残余应力的影响曲线(f = 0.09 mm/r，ap = 0.10 mm)

Fig. 16 Influence of cutting speed on residual stress (f = 0.09 mm/r, ap = 0.10 mm)

图17 莫尔圆分析法

Fig. 17 Mohr’s circle method

表4 残余主应力最小值计算结果与测量结果对比

Table 4 Calculation and measurement results of minimum residual principal stress

试验序号	σ_min方向角α₂/(°)	σ_min计算值/MPa	σ_min测量值/MPa	偏差/%
1-3	-45.1	-880	-912	3.64
1-4	-47.9	-929	-1027	10.49
2-3	-46.4	-934	-876	6.22
2-4	-48.6	-995	-920	7.52
3-1	-46.8	-871	-830	4.73

图18 切削参数对残余主应力最大值方向角的影响曲线

Fig. 18 Influence of cutting parameters on direction angle of maximum residual principal stress

图19 切削速度对加工表面显微硬度的影响曲线

Fig. 19 Influence of cutting speed on microhardness of machined surface

图20 显微硬度沿层深分布曲线

Fig. 20 Distribution of microhardness along the depth of subsurface layer

表5 硬车削与磨削工艺对比

Table 5 Comparison of hard turning and grinding processes

工艺	Q_z /(mm³·min^-1)	Ra /μm	残余应力σ/MPa
工艺	Q_z /(mm³·min^-1)	Ra /μm	轴向	周向
硬车削	1080	0.75	-476	-474
磨削^[20]	80	0.5-0.7	-312	-249

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