金刚石砂轮高速磨削工业纯铁技术研究

金刚石作为最理想的刀具材料在常规条件下却不可用于加工工业纯铁，这是由于加工表面差以及加工亚表面损伤大，并且刀具磨损严重。高速加工技术可以改善材料的加工性能，已成功用于多种难加工材料的加工。因此本文将高速加工技术应用于金刚石砂轮磨削工业纯铁，探究工业纯铁的加工特性。本文的主要研究成果如下：

基于Abaqus仿真软件研究了单颗金刚石磨粒在划擦工业纯铁的过程中产生的温度、应力、划擦力。仿真结果发现，产生的温度、应力、划擦力均随划擦速度的升高而增大。开展了划擦速度为10.0-210.0 m/s的单颗金刚石磨粒划擦工业纯铁的实验研究，并对划擦表面及金刚石磨粒进行了表征研究。研究结果表明，划擦表面粗糙度数值随划擦速度的升高而减小，Ra最小为0.177 µm；金刚石磨粒的磨损体积由磨粒与工件的接触时间及产生的温度、应力的耦合作用而决定，当划擦速度为160.0 m/s时，磨粒的磨损体积最小，为23440.4 µm³。

开展了磨削速度为5.4-32.4 m/s的金刚石砂轮平面磨削工业纯铁的实验研究，并对磨削样品的表面完整性进行了研究。研究结果表明，随着磨削速度的提高，磨削表面粗糙度数值和硬度值降低，Ra最小为0.194 µm，最低硬度为165.3 HV；在磨削亚表面的微观组织特征依次为晶粒细化层、晶粒拉长变形层、基体材料层，其纳米压痕硬度依次下降。

开展了磨削速度为58.0-243.2 m/s的金刚石砂轮外圆磨削工业纯铁的实验研究，并对磨削样品的表面完整性进行了研究，获得了磨削速度对金刚石砂轮磨削工业纯铁表面完整性的影响规律。研究结果表明，当磨削速度为181.5 m/s时，粗糙度数值最低，Ra值为0.362 µm，磨削表面硬度随磨削速度的增加而减小，最低硬度值为166.1 HV；晶粒细化层的厚度随磨削速度的增大先减小后增大，当磨削速度为181.5 m/s时，晶粒细化层的厚度最小，大约为1.72 µm。在磨削过程中，随着磨削速度的提高，磨粒的有效磨削深度会降低，导致磨削力下降，磨削表面质量变好；磨削亚表面的晶粒细化由动态再结晶所导致，由磨削力与磨削温度耦合作用而决定。

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