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complementary machining - simulation based analysis of a mechanical surface treatment integrated in a machining process for the intended formation of nanocrystalline surface layers

补充加工 - 基于模拟的机械表面处理分析，集成在加工过程中，旨在形成纳米晶体表面层

基本信息

批准号：
242346722
负责人：
Professor Dr.-Ing. Frederik Zanger
金额：
--
依托单位：
Institut für Produktionstechnik (WBK)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2013
资助国家：
德国
起止时间：
2012-12-31 至 2021-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/242346722?language=en
关键词：
complementary machining simulation based analysis

项目摘要

The aim of the research project is the application of the process strategy Complementary Machining on the technically relevant production process turning. Rotationally symmetric components like shafts made of the quenched and tempered steel AISI 4140 (42CrMo4) often represent highly stressed components whose surfaces are treated in a further process step after machining in order to ensure the desired properties. Component characteristics like the topography to optimize the tribological behavior or the service life of the parts are technically relevant target values. The component characteristics are usually achieved by expensive post production processes like deep rolling or hammer peening. With Complementary Machining the surface treatment is proceeded after machining without changing tools, by reversing the cutting direction and treating the surface of the component with the machining tool. Due to an extremely negative rake angle plastic deformation in the surface layer of the component is induced. In this way surface hardening as well as changes in microstructure can be achieved.Applying the process strategy Complementary Machining on the technically relevant production process turning leads to significantly more complex contact conditions. Thereof new challenges in terms of tool geometry and the demand for a robust process control result.Due to a suitable micro- and macroscopic design of cutting edges and an adaptable tool holder contact conditions are to be optimized since component conditions can be specifically adjusted and tool wear can be reduced to an economically acceptable level. For this purpose investigations of the tool material (WC-Co) with different grain sizes are planned. In order to increase tool life and precisely control component conditions in the surface layer the influence of cryogenically cooled Complementary Machining is to be analyzed. Using cryogenic cooling the potential of strain hardening is supposed to be significantly improved. Based on these findings a process guideline for producing shafts made of the quenched and tempered steel AISI 4140 (42CrMo4) will be derived.The planned investigations are intended to make significant contributions to a better understanding of interactions between the micro- and macroscopic design of cutting edges, their microstructure and component conditions that are achieved with Complementary Machining. Based on these findings considering a process with an ideal cryogenic cooling system the industrial relevance of Complementary Machining is to be demonstrated.

研究项目的目的是将工艺策略互补加工应用于与技术相关的车削生产过程。旋转对称部件，如由淬火和回火钢AISI 4140 （42CrMo4）制成的轴，通常代表高应力部件，其表面在加工后的进一步工艺步骤中进行处理，以确保所需的性能。部件特性，如优化摩擦学行为的地形或部件的使用寿命，在技术上是相关的目标值。部件的特性通常是通过昂贵的后期加工过程，如深滚或锤击强化来实现的。互补加工是在加工后不更换刀具的情况下，通过反转切削方向，用刀具对零件表面进行处理，从而进行表面处理。由于极负的前角，构件的表层会产生塑性变形。通过这种方式可以实现表面硬化和微观结构的变化。将互补加工策略应用于与技术相关的生产过程车削，会导致接触条件明显复杂化。因此，在刀具几何形状和对鲁棒过程控制结果的需求方面提出了新的挑战。由于合适的切削刃微观和宏观设计以及适应性强的刀架，接触条件将得到优化，因为部件条件可以具体调整，刀具磨损可以减少到经济上可接受的水平。为此，计划对不同晶粒尺寸的刀具材料（WC-Co）进行研究。为了提高刀具寿命和精确控制表层零件状态，分析了低温冷却互补加工对刀具寿命的影响。低温冷却可显著提高材料的应变硬化潜力。在此基础上，提出了用AISI 4140 （42CrMo4）调质钢制造轴的工艺指南。计划中的研究旨在为更好地理解切削刃的微观和宏观设计之间的相互作用、它们的微观结构和部件条件之间的相互作用做出重大贡献，这些都是通过互补加工实现的。基于这些发现，考虑到一个具有理想低温冷却系统的过程，互补加工的工业相关性将被证明。