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摘要: 在高速切削加工铝合金涡轮过程中，硬质合金刀具的磨损会直接影响刀具的使用寿命和加工精度，导致加工精度无法满足设计要求，在磨损严重时还会引起刀具和零件的损伤。本文以高效切削铝合金涡轮用硬质合金刀具为研究对象，通过四因素三水平正交试验对刀具磨损行为进行研究，观测和分析不同切削参数下硬质合金刀具的磨损状态及微观形貌，讨论并提出有效控制刀具磨损的措施。结果表明，该控制刀具磨损的措施在保证零件加工精度的同时具有一定的实际推广价值。Abstract: In the high-speed cutting process of aluminum alloy turbine by carbide tools, the wear characteristics of carbide tools directly affect the service life and machining accuracy, resulting in that the machining accuracy cannot reach the design requirements. In addition, the serious wear may lead to the damage of tools and parts. The carbide tools used for high-speed cutting aluminum alloy turbine were investigated in this paper, the four-factor three-level orthogonal tests were used to studied the wear performance of carbide tools. The wear state and microstructures of carbide tools were observed and analyzed in different cutting parameters. The improvement measures were discussed and proposed to effectively control the tool wear. In the results, the improvement measures can ensure the machining accuracy of parts, and have the practical value to popularize.
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Key words:
- cemented carbide /
- tool /
- wear /
- high-speed cutting /
- aluminum alloy
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图 1 实验设备及刀具：（a）VH-8000数字光学显微镜；（b）机夹式立铣刀
Figure 1. Experimental equipments and tools: (a) optical microscope (VH-8000); (b) clip-type end mill
图 2 不同切削参数下NASKA刀片崩刃现象：（a）fz = 0.3 mm，ap = 1 mm，ae = 11 mm，Vc = 942 m/min；（b）fz = 0.3 mm，ap = 2 mm，ae = 7 mm，Vc = 471 m/min
Figure 2. Images of blade chipping in different cutting parameters: (a) fz = 0.3 mm, ap = 1 mm, ae = 11 mm, Vc = 942 m/min; (b) fz = 0.3 mm, ap = 2 mm, ae = 7 mm, Vc = 471 m/min
图 3 刀具（a）和后刀面（b）黏结磨损宏观形貌（fz = 0.3 mm，ap = 1 mm，Vc = 706 m/min）
Figure 3. Adhesive wear images of tool (a) and cutter flank (b) at fz = 0.3 mm, ap = 1 mm, and Vc = 706 m/min
图 4 黏结物显微组织形貌及能谱分析：（a）扫描电子显微形貌；（b）能谱分析
Figure 4. Microstructures and composition of adhesive substance: (a) SEM morphology; (b) EDS analysis
图 5 后刀面磨损处显微组织形貌及能谱分析：（a）扫描电子显微形貌；（b）能谱分析
Figure 5. Microstructures and composition in wear zone: (a) SEM morphology; (b) EDS analysis
表 1 NASKA刀片正交实验参数与因素水平
Table 1. Parameters and levels in orthogonal experiment of NASKA blade
因素水平 切削深度，ap / mm 线速度，Vc / (m·min-1) 每齿进给，fz / mm 切削宽度，ae / mm 1 1 471 (刀具转速：6000 r/min) 0.1 3 2 3 706 (刀具转速：9000 r/min) 0.2 7 3 2 942 (刀具转速：12000 r/min) 0.3 11 
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表 2 SANDVIK刀片正交实验因素与水平
Table 2. Parameters and levels in orthogonal experiment of SANDVIK blade
因素水平 切削深度，ap / mm 线速度，Vc / (m·min-1) 每齿进给，fz / mm 切削宽度，ae / mm 1 1 471 (刀具转速：6000 r/min) 0.1 3 2 2 706 (刀具转速：9000 r/min) 0.2 8 3 3 942 (刀具转速：12000 r/min) 0.3 13
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表 3 NASKA刀片正交实验结果分析
Table 3. Analysis on orthogonal experiment results of NASKA blade
切削参数 切削深度，ap 线速度，Vc 每齿进给，fz 切削宽度，ae 因素水平 1 2 3 1 2 3 1 2 3 1 2 3 ∑T 0.288 0.342 0.306 0.27 0.306 0.369 0.261 0.288 0.396 0.276 0.297 0.36 均值 0.096 0.114 0.102 0.09 0.102 0.123 0.087 0.096 0.132 0.093 0.099 0.12 极差 0.018 0.033 0.045 0.027 注：∑T表示的是切削参数对刀具后刀面磨损量影响程度的总和，均值表示的是切削参数对刀具后刀面磨损量影响程度的平均值，极差表示的是切削参数对刀具后刀面磨损量的影响程度。
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