目的 在GH4065A高温合金涡轮盘拉削加工过程中,拉刀结构及拉削参数设计不当常会导致拉削过程中产生涡轮盘加工精度低、拉削应力过大等难题。为了解决这些问题,对拉刀结构及拉削参数进行进一步的研究。方法 针对GH4065A高温合金涡轮盘榫槽拉削加工中的工艺优化问题,通过有限元仿真与实验相结合的方法,系统研究了拉削速度（vc）、齿升量（a）和刀具前角（B）对材料去除率（MRR）、切削力（Fz、Fy）、切削温度（T）、刀具磨损及表面粗糙度的影响规律。结果 MMR随齿升量和拉削速度的增加显著提升,但高MRR工况（如vc=2 m/min, a=0.04 mm）伴随高温（242 ℃）和切削力波动,而中等参数组合（vc=2 m/min, a=0.02 mm）可实现效率与稳定性的平衡（Fz=16.7 kN, Fy=5.43 kN, T=57.5 ℃）。最优表面粗糙度（Ra=1.804 μm）出现在高切削速度与中齿升量组合下,而低速或极端参数导致粗糙度恶化（2.398~2.617 μm）。结论 基于多目标优化,提出采用“高速中齿升量（vc=2 m/min, a=0.02 mm）+适中前角（15°~18°）”的工艺策略,并辅以冷却控制,为航空发动机涡轮盘榫槽的高效低应力高精度加工提供了理论依据。
Abstract
In the machining process of GH4065A superalloy turbine discs, improper design of the cutting tool structure and cutting parameters often leads to problems such as low machining accuracy of the turbine disc and excessive cutting stress during the cutting process. The work aims to solve these problems through further research on the structure of the cutting tool and the cutting parameters. Focusing on the process optimization problem in the machining of GH4065A superalloy turbine disc tenon grooves, and through a combination of finite element simulation and experiment, the influence of machining speed (vc), tooth lift (a), and tool rake angle (B) on material removal rate (MRR), cutting force (Fz, Fy), cutting temperature (T), tool wear, and surface roughness was systematically studied. The research results showed that MMR significantly improved with the increase of tooth lift and cutting speed, but high MRR conditions (such as vc=2 m/min, a=0.04 mm) were accompanied by high temperature (242 ℃) and cutting force fluctuations, while a medium parameter combination (vc=2 m/min, a=0.02 mm) could achieve a balance between efficiency and stability (Fz=16.7 kN, Fy=5.43 kN, T=57.5 ℃). The optimal surface roughness (Ra=1.804 μm) occurred in the combination of high cutting speed and medium tooth lift, while low speed or extreme parameters led to roughness deterioration (2.398-2.617 μm). This study is based on multi-objective optimization and proposes a process strategy of “high-speed medium tooth lift (vc=2 m/min, a=0.02 mm)+moderate rake angle (15°-18°)”, supplemented by cooling control, to provide a theoretical basis for efficient, low stress, and high-precision machining of aircraft engine turbine disc tenon grooves.
关键词
GH4065A高温合金 /
拉削加工 /
材料去除率 /
切削力 /
刀具磨损 /
表面粗糙度
Key words
GH4065A superalloy /
broaching /
material removal rate (MRR) /
cutting force /
tool wear /
surface roughness
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基金
四川省重大科技专项（2021ZDX0007）
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