Study on removal mechanism of steel bonded cemented carbide material GT35 in cutting process
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摘要: 为研究金刚石磨粒刀具切削钢结硬质合金GT35的微观刻划过程与材料去除机理，以单颗粒金刚石刻划实验为研究手段，分析其微观切削力的影响因素及材料的微观去除过程。通过单颗粒金刚石变切深实验发现，切削力与切痕截面积之间呈线性关系，获得的线性比例系数k的估计值可通过单颗粒金刚石等切深实验修正。随后，通过扫描电镜对GT35材料表面切痕形貌进行观测，并用激光共聚焦显微镜对其形貌进行三维建模，研究不同刻划深度下的材料去除模式。结果表明：修正后k(Fx)为0.026 29 N/μm2（R1=0.990 46），k(Fz)为0.046 42 N/μm2（R2=0.994 08）； 调质GT35材料在多种切深下均以塑性去除为主，其中切痕底面呈现明显塑性剪切去除状态，切痕边缘位置呈现一定的脆性断裂状态。刀具在切削过程中会在刀尖处形成材料堆叠死区，引起刀具崩刃及磨损，且切痕表面形貌的形成与刀具磨损密切相关。
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关键词:
- 单颗粒金刚石切削 /
- GT35钢结硬质合金 /
- 切削力模型 /
- 材料去除模式 /
- 磨削
Abstract: Single particle diamond cutting experiments are designed to research the micro scratching process and material removal mechanism of GT35 steel bonded cemented carbide. The value of linear scale coefficient k is estimated as well. The exact value of k is further confirmed by equal depth cutting experiment. Furthermore, the material removal approaches at different cutting depths are discussed by microscopic observation and three-dimensional morphology modeling by SEM and laser confocal microscope. It is observed that there is a linear functional relationship between cutting force and groove cross-sectional area. k (Fx) is 0.026 29 N/μm2(R2=0.990 46) and k (Fz) is 0.046 42 N/μm2(R2=0.994 08) after fitting. The quenched and tempered GT35 material is mainly plastic removal under various cutting depths, in which the bottom surface of the groove shows an obvious plastic shear removal state, and the edge shows a certain brittle removal state. During the cutting process, there will form a material stacking dead zone at the tool tip, causing tool edge collapse and wear. The formation of the surface morphology is closely related to tool wear. -
图 1 GT35颗粒增强金属基复合材料微观组织
Figure 1. Microstructure of GT35 particle reinforced metal matrix composites
图 2 调质GT35材料中TiC颗粒的微观结构（钢基体腐蚀处理）
Figure 2. Microstructure of TiC particles in quenched and tempered GT35 material (corrosion treatment of steel substrate)
图 4 单颗粒金刚石刻划GT35实验设置
Figure 4. Experimental setup of single particle diamond scratching test for GT35
图 8 切深及截面积随刻划长度变化示意图
Figure 8. Variation of cutting depth and groove cross-sectional area with scraching length
图 9 变切深切痕截面积随时间变化
Figure 9. Variation of cross-sectional area of variable depth cutting
图 10 变切深实验切削力随时间变化
Figure 10. Cutting force of variable depth cutting experiment changes with time
图 11 切削力及比例系数k随时间变化图像
Figure 11. Variation trend of cutting force and proportional coefficient k with time
图 13 不同切深下的切痕截面积变化趋势及相对标准误差RSD
Figure 13. Variation trend and relative standard error (RSD) of cross-sectional area under different cutting depths in equal cutting depth experiment
图 14 Fx2及Fz2与切痕截面积S2的关系图
Figure 14. Relationship between Fx2/Fz2 and cross-sectional area S2
图 16 金刚石刀具刻划调质GT35材料的缺陷产生过程
Figure 16. Material uplift and stacking process at the edge of the scratch
图 17 切痕边缘材料隆起及堆叠过程
Figure 17. Generation process of material surface defects in diamond tool cutting
图 19 单颗粒锥形金刚石磨粒刀具刻划实验前后形貌对比
Figure 19. Comparison of morphology of single particle conical diamond abrasive tool before and after scraching experiment
参数 数值 TiC 质量分数 ω1 / % 35.0 Cr 质量分数 ω2 / % 2.0 Mo 质量分数 ω3 / % 2.0 C 质量分数 ω4 / % 0.5 Fe 质量分数 ω5 / % 余量 
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表 2 切削参数设置
Table 2. Cutting parameter setting
参数 数值 切削速度 v / (mm·s−1) 75 等切深 ap1 / μm 1.000，5.000，10.000，15.000，20.000 变切深 ap2 / μm 0～5.000
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