双层材料多道次磨削参数规划软件开发

Software development for multi-pass grinding parameter planning of gradient bilayer materials

  • 摘要: 在工件表面喷涂耐磨涂层可显著提高工件的耐磨损性能,但后续磨削过程中涂层-基体异质材料接触界面会导致热传导不连续,进而产生热应力,因此需要设置合理的磨削工艺参数以严格控制涂层-基体接触界面的温度。文章针对超音速火焰喷涂(high-velocity oxygen fuel, HVOF)涂层磨削过程中涂层-基体接触界面温度控制问题开展研究,并开发多道次磨削参数规划软件。首先通过正交试验数据拟合得到切向磨削力经验公式,揭示了砂轮线速度vs、进给速度vw、磨削深度ap对磨削力的影响规律;其次利用Ansys建立磨削热仿真模型,分析得出双层材料接触界面温度与磨削参数及涂层厚度的关系模型;最后以接触界面磨削温度恒定为目标开发磨削参数规划软件。经过测试验证,软件运行结果符合预期。

     

    Abstract: The wear resistance of workpieces can be significantly improved by spraying wear-resistant coatings on their surfaces. However, during subsequent grinding, the contact interface between the coating and substrate (heterogeneous materials) causes discontinuous heat conduction, leading to thermal stress. Thus, it is necessary to set reasonable grinding parameters to strictly control the temperature at the coating-substrate interface. The temperature control of the coating-substrate interface during high-velocity oxygen fuel (HVOF) coating grinding was focused on, and multi-pass grinding parameter planning software was developed. Firstly, an empirical formula for tangential grinding force was obtained by fitting orthogonal experimental data, revealing the influence of grinding wheel linear velocity vs, feed rate vw, and grinding depth ap on grinding force. Secondly, a grinding heat simulation model was established using Ansys based on the moving heat source theory and triangular distribution heat source model. A relational model was analyzed to link the interface temperature of double-layer materials with grinding parameters and coating thickness. Finally, grinding parameter planning software was developed to maintain constant interface temperature during multi-pass grinding. Testing and verification showed that the software operation results met expectations.

     

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