Prediction model of surface integrity characteristics in ball end milling TC17 titanium alloy
Prediction model of surface integrity characteristics in ball end milling TC17 titanium alloy
复制标题
TC17钛合金球头铣削表面完整性特征预测模型
DOI：
10.1007/s40436-022-00416-y
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发表时间：
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影响因子：
5.2
通讯作者：
Dinghua Zhang
中科院分区：
文献类型：
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作者：
Xuehong Shen;Changfeng Yao;Liang Tan;Dinghua Zhang
表面完整性对提高构件的疲劳性能具有重要意义。正确选择切削参数对于确保高表面完整性极为重要。本文采用响应面法对TC 17钛合金进行了球头铣削加工。研究了切削速度、每齿进给量、切削深度和切削宽度对表面完整性特征（包括表面粗糙度（Ra）、表面形貌、残余应力和微观结构）的影响。此外，提出了作为铣削参数的函数的表面粗糙度、残余应力和显微硬度的预测元模型。实验结果表明，随着铣削参数的增加，表面粗糙度增大，沿进给方向的Ra值为0.4 ~ 1.2 μm，沿着进给方向的Ra值远低于沿沿着截齿进给方向的Ra值。随着每齿进给量、切削深度和切削宽度的增加，表面残余压应力增大，而在高切削速度下，表面残余压应力减小。残余压应力层深度主要在25-40 μm之间。铣削后的表面显微硬度为初始状态的6.4%，加工硬化层深度约为20 μm。此外，在表面以下3 μm深度范围内观察到塑性变形和应变流线。表面完整性特性的经验模型是利用十个实验的结果开发的，并通过两个额外的实验进行验证。三个表面完整性特征的预测误差均在27%以内，显微硬度经验模型的预测误差最小。
Surface integrity is important to improve the fatigue property of components. Proper selection of the cutting parameters is extremely important in ensuring high surface integrity. In this paper, ball end milling of TC17 alloy has been carried out utilizing response surface methodology. The effects of cutting speed, feed per tooth, cutting depth, and cutting width on the surface integrity characteristics, including surface roughness (Ra), surface topography, residual stress, and microstructure were examined. Moreover, predictive metamodels for surface roughness, residual stress, and microhardness as a function of milling parameters were proposed. According to the experimental results obtained, the surface roughness increases with the increase of milling parameters, the (Ra) values vary from 0.4 μm to 1.2 μm along the feed direction, which are much lower compared to that along the pick feed direction. The surface compressive residual stress increases with the increase of feed per tooth, cutting depth, and cutting width, while that decreases at high cutting speed. The depth of the compressive residual stress layer is mostly in the range of 25–40 μm. The milled surface microhardness represents 6.4% compared with the initial state; the work-hardened layer depth is approximately 20 μm. Moreover, plastic deformation and strain streamlines are observed within 3 μm depth beneath the surface. The empirical model of surface integrity characteristics is developed using the results of ten experiments and validated by two extra experiments. The prediction errors of the three surface integrity characteristics are within 27%; the empirical model of microhardness has the lowest prediction errors.