Numerical simulation of multi-principal elements high-entropy alloy milling based on minimal quantity lubrication
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摘要: 为研究微量润滑对多主元高熵合金铣削力的影响，建立高熵合金与四刃立铣刀的热力耦合单刃铣削模型，通过分析材料去除机理揭示微量润滑降低铣削力的作用机制，并开展单因素实验研究不同铣削参数对铣削力的影响规律。结果表明：在铣削深度为0.15～0.20 mm时，微量润滑铣削相较于干式铣削几乎不降低铣削力；在铣削深度＞0.20 mm时，随着铣削深度增加，微量润滑降低铣削力的效果增强；在铣削深度为0.30 mm时，可降低约30%的铣削力。同时，铣削力随着每齿进给量和铣削深度的增加而增大，且随铣削深度逐渐增加，铣削力对每齿进给量增大的敏感程度逐渐加剧。Abstract:
Objectives High-entropy alloys (HEA) with multi-principal elements have many excellent characteristics such as high strength, high hardness and high wear resistance, which have attracted widespread attention from scholars. However, the mechanical processing of HEA is difficult. This study utilizes minimal quantity lubrication (MQL) technology for milling HEA to improve their machining performance and explore the influences of different milling parameters on their milling force. Methods The thermodynamic coupling milling model of HEA (CoCrFeNiMn) and a four-edge end milling cutter is established using finite element simulation software. The difference in milling force between MQL milling and dry milling is studied by analyzing the material removal mechanism, and the influences of different milling parameters on milling forces are studied by single-factor experiments. Firstly, the three-dimensional model of the four-edge end milling cutter, the J-C constitutive model of HEA (CoCrFeNiMn), the heat conduction model and the contact friction model are established, and the material failure separation criteria are determined and the milling model is established. Then, the material removal mechanism under the thermodynamic coupling condition is analyzed, and the changes in milling forces between MQL milling and dry milling are analyzed from the perspectives of equivalent stress, contact friction and the thermal softening effect, and the advantages of MQL technology for milling HEA (CoCrFeNiMn) are analyzed. Finally, the effects of feed speed, spindle speed and milling depth on milling force are obtained by single-factor tests. Results Through comparative experiments between dry milling and MQL milling, it is found that: (1) The equivalent stress produced by the two milling methods are concentrated in the first deformation zone, and the equivalent stress of dry milling is also concentrated in the position near the cutting edge. (2) The equivalent stress value of MQL milling in the first deformation zone is slightly greater than that of dry milling. (3) The heat generated by the two milling methods is concentrated in the first deformation zone and the chips, and the chips take away most of the heat. The chip temperature generated by dry milling is significantly higher than that generated by MQL milling. (4) MQL milling significantly reduces the temperature at the cutting site and improves chip integrity. (5) When the milling depth is 0.15 to 0.20 mm, the milling force of MQL milling is basically the same as that of dry milling. When the milling depth is greater than 0.20 mm, the ability of MQL milling to reduce milling force increases with the increase of milling depth. This is due to the use of MQL technology in the milling process, which compensates for the reduced milling force caused by low friction coefficient and the increased milling force caused by weak thermal softening effect. The MQL milling single-factor tests show that: (1) The milling force increases with the increase of feed speed, and decreases with the increase of spindle speed, that is, it increases with the increase of feed rate per tooth. (2) The milling force increases with the increase of milling depths, and the effect of feed rate per tooth on the average milling force is gradually intensified with the increase of milling depth. Conclusions The MQL milling has obvious advantages, which can significantly reduce milling force at milling depth greater than 0.20 mm, and the ability to reduce milling force increases with the increase of milling depth. In addition, the use of MQL technology in the milling process can significantly reduce the temperature at the cutting position, improve HEA machining accuracy, and avoid a series of defects of traditional pouring lubrication. The cutting force in MQL milling conforms to the change law of cutting force in most metal milling with the process parameters. In MQL milling, the milling force can be further reduced by increasing the spindle speed and reducing the feed speed. When the milling depth is large, the spindle speed should be further increased and the feed speed should be reduced to reduce the feed per tooth, in order to deal with the high sensitivity of the milling force to the milling depth. -
图 5 干式铣削下X、Y、Z 3个坐标轴方向的铣削力分布
Figure 5. Distribution of dry milling forces in X,Y,Z three axis directions
图 6 不同铣削深度下的X轴方向平均铣削力对比
Figure 6. Comparison of average milling forces in X-axis direction at different milling depths
图 7 进给速度对X轴方向平均铣削力的影响
Figure 7. Influences of feed rates on average milling forces in X-axis direction
图 8 主轴转速对X轴方向平均铣削力的影响
Figure 8. Influences of spindle speeds on average milling forces in X-axis direction
图 12 进给速度对X轴方向平均铣削力的影响
Figure 12. Influences of feed rates on average milling forces in X-axis direction
图 13 不同铣削深度下每齿进给量对X轴方向平均铣削力的影响
Figure 13. Effects of feed per tooth on average milling forces in X-axis direction at different milling depths
表 1 铣刀模型主要参数
Table 1. Main parameters of milling cutter model
刀具参数名称 参数值 $ {\gamma }_{0} $ / (°) 45 $ {\alpha }_{0} $ / (°) 20 $ {\gamma }_{1} $ / (°) 0 $ {\alpha }_{1} $ / (°) 20 $ \beta $ / (°) 45 $ {Z}_{{\mathrm{n}}} $ 4 $ {L}_{1} $ / mm 1 $ {D}_{{\mathrm{c}}} $ / mm 2 $ {b}_{{\mathrm{a}}1} $ / mm 0.08 
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表 2 CoCrFeNiMn的J-C本构模型参数
Table 2. J-C constitutive model parameters of CoCrFeNiMn
本构模型参数 取值 A / MPa 620 B / MPa 1820 C 0.38 n 0.78 m 0.71
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表 3 不同润滑方式下的摩擦系数
Table 3. Friction coefficients under different lubrication modes
润滑方式 摩擦系数 μ MQL铣削 0.4 干式铣削 0.6
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表 4 热传导模型参数
Table 4. Parameters of heat conduction model
类型 比热容
$ c $ / (J·kg−1·K−1)热导率
$ \lambda $ / (W·m−1·K−1)非弹性热
份额 $ {W}_{{\mathrm{h}}} $膜层散热系数
h / (W·m−2·K−1)工件 565 10 0.9 300 铣刀 176 79 0.9 80
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