Effects of Process Parameters on White Layer Formation and Morphology in Hard Turning of AISI52100 Steel
Effects of Process Parameters on White Layer Formation and Morphology in Hard Turning of AISI52100 Steel
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工艺参数对AISI52100钢硬车削白层形成及形貌的影响
DOI：
10.1115/1.4032769
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发表时间：
2016-07
期刊：
影响因子：
--
通讯作者：
Han Ding
中科院分区：
文献类型：
--
作者：
Xiao-Ming Zhang;Li Chen;Han Ding
硬车削越来越被工业界视为磨削的潜在替代品。然而，它极大地阻碍了表面完整性问题，如拉伸残余应力和白色层，这通常被发现对加工零件的应力腐蚀，耐磨性和疲劳寿命有负面影响。本文研究了硬车削过程中白色层的形成和形态，采用不同的工艺参数，考虑到热处理的影响，导致显微组织和硬度的差异上的散装材料。制备了经历三种典型热处理工艺的样品，然后使用不同的切削速度和径向进给速率进行加工。采用光学显微镜、扫描电镜（SEM）和X射线衍射（XRD）分析了不同热处理和切削工艺后的白色层和块体材料的显微组织。通过研究，我们发现存在一个切削速度阈值，低于该阈值，无论是低温回火还是中温回火，都不会形成白色层。阈值增大;然而，在相同的切削条件下，分别进行低温回火和中温回火，白色层厚度减小。另外，我们还发现表面上的白色层厚度及其沿着切削方向的分布随切削速度和径向进给量的增加而增加。在高速切削条件下淬火后的试样中可以观察到具有波浪状形貌的白色层。首次发现波形白色层的螺距与锯齿状切屑形成时刀具的位移近似。同时，测量了试样的表面残余应力。给出了白色层与残余应力的关系。基于这种关系，我们揭示了高温比体积膨胀更主导白色层的形成。
Hard turning is becoming increasingly considered by industry as a potential substitute for grinding. However, it is greatly hurdled by surface integrity problems such as tensile residual stress and white layer, which are generally found to have negative effects on the stress corrosion, wear resistance, and fatigue life of the machined parts. This paper investigates white layer formation and morphology in hard turning process using various process parameters, taking into account the effects of heat treatment which results in microstructure and hardness differences on bulk materials. Samples undergone three typical heat treatment processes are prepared and then machined using different cutting speeds and radial feed rates. Optical microscope, scanning electron microscope (SEM), and X-ray diffraction (XRD) are employed to analyze the microstructures of white layer and bulk materials after varies heat treatments and cutting processes. Through the studies, we find the existence of a cutting speed threshold, below which no white layer forms for both the low and medium-temperature tempering. The threshold value increases; however, the white layer thickness decreases under the same cutting conditions, for the low and medium-temperature tempering, respectively. Also, we find that the white layer thickness and the scattering of it along the cutting direction on the surface increases with cutting speed and radial feed rate. White layer with wavy morphology can be found in samples after quenching at high cutting speed. We first discover that the pitch of the white layer with wavy morphology is similar to the displacement of tool at the time a segment of the serrated chips forms. Also, the surface residual stresses of the samples are measured. Relationship between white layer and residual stresses is presented. Based on the relationship we reveal that high temperature is more dominant than volume expansion for white layer formation.
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DOI：
10.1016/s0007-8506(07)61467-x
发表时间：
2002
期刊：
CIRP Annals
影响因子：
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作者：
J. Barry;G. Byrne
通讯作者：
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DOI：
10.1007/s00170-006-0899-2
发表时间：
2008-03
期刊：
The International Journal of Advanced Manufacturing Technology
影响因子：
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作者：
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DOI：
10.1115/1.4027816
发表时间：
2014-10
影响因子：
4
作者：
Tang B. T.;Wang Q. L.;Bruschi S.;Ghiotti A.;Bariani P. F.
通讯作者：
Bariani P. F.
DOI：
10.1016/0025-5416(75)90010-5
发表时间：
1975-01-01
期刊：
MATERIALS SCIENCE AND ENGINEERING
影响因子：
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作者：
TURLEY, DM
通讯作者：
TURLEY, DM
DOI：
10.1243/09544054jem1179
发表时间：
2008-11
期刊：
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
影响因子：
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作者：
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S. Iqbal;P. Mativenga;M. Sheikh