金刚石磨粒切削钢混材料的温度仿真分析与磨损实验

韦敏; 史永晋; 郭子航

doi:10.13394/j.cnki.jgszz.2024.0128

金刚石磨粒切削钢混材料的温度仿真分析与磨损实验

doi: 10.13394/j.cnki.jgszz.2024.0128

韦敏^{1, 2,},
史永晋³,
郭子航⁴

1.
中国海洋大学海洋地球科学学院, 山东青岛 266100
2.
中国石化胜利油田分公司海洋采油厂, 山东东营 257237
3.
中石化胜利石油工程有限公司钻井工艺研究院, 山东东营 257237
4.
哈尔滨工程大学机电工程学院, 哈尔滨 150001

详细信息

作者简介:
韦敏，男，1983年生，在读博士，高级工程师。主要研究方向：海上油气开发及管理。E-mail：weimin.slyt@sinopec.com

中图分类号: TE952; TG58; TG74
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- 文章访问数: 10
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- 被引次数: 0
出版历程
- 收稿日期: 2024-08-20
- 修回日期: 2024-09-14
- 录用日期: 2024-10-21
- 刊出日期: 2025-06-30

Temperature simulation analysis and wear experimental of diamond abrasive grains cutting steel mixed materials

WEI Min^{1, 2
,},
SHI Yongjin³,
GUO Zihang⁴

1.
College of Marine Geosciences, Ocean University of China, Qingdao 266100, Shandong, China
2.
China Petroleum and Chemical Corporation Shengli Oilfield Branch Offshore Oil Production Plant, Dongying 257237, Shandong, China
3.
Drilling Technology Research Institute, Sinopec Shengli Petroleum Engineering Co., Ltd., Dongying 257237, Shandong, China
4.
College of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, China

摘要

摘要: 海上平台导管架桩基一般采用钢混灌浆结构，在利用金刚石串珠绳切割其海面以上部分时，为确保单根串珠绳完成单一切口的切割作业，必须选择合理的冷却方案。本研究基于傅里叶导热定律建立金刚石磨粒切削温度场数值模型，该温度场的温度随切削工艺参数的增大而升高，随介质参数的增大而降低；利用AdvantEdge有限元切削仿真技术建立金刚石磨粒切削钢混材料的动力学仿真模型，探究切削过程中不同冷却方式对切削区温升和磨粒磨损的影响；搭建金刚石串珠绳切削实验台，根据实际工况，选择了干切削、低温喷雾和高压水冷3种切削方式，对仿真结果进行实验验证。结果表明：低温喷雾冷却方案的冷却效果最优，与干切削相比，试验后单颗串珠磨粒的完整度可提高13百分点，磨粒脱落率可降低15百分点。因此，在导管架平台桩基切割工况下，选择低温喷雾冷却的方式，更有利于串珠绳切削效率和使用寿命的提升。
- 金刚石串珠绳 /
- 磨粒 /
- 冷却方式 /
- 切削温度 /
- 磨粒失效
Abstract: Objectives Diamond wire saw cutting, being environmentally friendly and unaffected by water depth, structure material, shape, or size, has become the preferred method for dismantling large oceanic structures. However, when cutting jackets above the water surface, the elevated temperatures in the cutting zone can lead to excessive wear on the wire saw and even result in cutting failure. To address this issue, this paper integrates theoretical, simulation, and experimental analyses to examine the impact of various cooling conditions on cutting zone temperature and tool wear. Furthermore, it identifies an optimal cooling method for the dismantling process of jackets using diamond wire saws on the sea surface. Methods First, based on the principles of thermal conductivity, a theoretical model of the temperature field in the cutting zone of diamond grains is developed to analyze the influence of cutting and media parameters on heat generation. Next, using AdvantEdge simulation software, a kinetic simulation model of diamond grit cutting reinforced concrete materials is established under various working conditions, including dry cutting, low-temperature air cooling, high-pressure water cooling, liquid nitrogen cooling, and low-temperature spray cooling. The temperature rise in the cutting zones under different cooling methods is analyzed. Finally, experimental cutting tests using diamond wire saws on reinforced concrete material workpieces are conducted to investigate the failure behavior and wear rate of the wire saws under different cooling conditions. The optimal cooling method is then identified and validates the simulation results. Results (1) According to the theoretical model of the temperature field in the cutting zone, the surface temperature increases with higher cutting parameters such as feed speed, cutting speed, and cutting time, while it decreases with the increase of medium parameters such as specific heat capacity and thermal conductivity. (2) The cutting simulation study indicates that under dry cutting conditions, the temperature in the cutting zone exceeds the diamond carbonization threshold, significantly compromising the cutting performance of the wire saw. In contrast, all four cooling methods maintain the cutting zone temperature below the diamond carbonization threshold, with low-temperature spray cooling demonstrating the most effective reduction in tool wear. (3) By measuring changes in the outer diameter of the beads on the wire saw, the lowest wear rate is observed under low-temperature spray cooling, which further validates the findings of the cutting simulation study. (4) Scanning electron microscope analysis of the worn diamond abrasive grains reveals four distinct behaviors of wear: intact abrasive grains, abrasive edge wear, surface fragmentation, and abrasive grain detachment. (5) Compared to dry cutting, low-temperature spray cooling increases the percentage of intact abrasive grains from 18% to 31% and reduces the abrasive grain detachment rate from 39% to 24%, thereby significantly enhancing cutting efficiency and extending the service life during diamond wire saw cutting of reinforced concrete materials. Conclusions When dismantling platform structures on the sea surface using diamond wire saws, low-temperature spray cooling is prioritized due to its minimal temperature rise in the cutting zone and the lowest bead wear rate. This approach significantly enhances cutting efficiency and extends the service life of the diamond wire saw.
- diamond beaded rope /
- abrasive grains /
- cooling method /
- cutting temperature /
- abrasive grain failure

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图 1 金刚石绳锯水面以上切割作业

Figure 1. Diamond rope saws for cutting operations above water

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图 2 三维导热微分图

Figure 2. Three-dimensional thermal conductivity differential diagram

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图 3 金刚石磨粒三维切削仿真模型

Figure 3. 3D cutting simulation model

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图 4 局部冷却源界面设置

Figure 4. Local cooling source interface settings

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图 5 干切削仿真的温度场分布

Figure 5. Temperature field distribution for dry cutting simulation

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图 6 磨粒温度仿真云图

Figure 6. Temperature simulation cloud of abrasive grains

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图 7 温度仿真结果

Figure 7. Temperature simulation results

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图 8 干切削下几何模型的压力场分布三维云图

Figure 8. 3D cloud map of pressure field distribution for geometric modeling under dry cutting

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图 9 串珠绳切削实验平台

Figure 9. Experimental platform for beaded rope cutting

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图 10 低温水雾化喷嘴与雾化效果图

Figure 10. Low-temperature water atomisation nozzle and atomisation effect diagram

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图 11 串珠平均直径随时间变化曲线

Figure 11. Curve of average diameter of beads over time

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图 12 串珠直径变化量

Figure 12. Amount of change in bead diameter

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图 13 扫描电镜下磨粒微观形貌

Figure 13. Microscopic morphology of abrasive grains under scanning electron microscopy

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图 14 金刚石磨粒磨损形式占比分布图

Figure 14. Distribution of diamond abrasive wear forms by percentage

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表 1 材料的属性参数表

Table 1. Property parameters of materials

材料	弹性模量 E / MPa	泊松比 v	比热容 c / (J·kg⁻¹·℃⁻¹)	导热系数 λ / (W·m⁻¹·K⁻¹)	热膨胀系数 α / (m·k⁻¹)
金刚石	1.10 × 10⁶	0.07	399.84	2 000	1.2 × 10⁻⁶
C40	3.25 × 10⁴	0.30	970.00	1.28	1.0 × 10⁻⁵

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表 2 C40钢筋混凝土材料的本构模型参数

Table 2. Parameters of intrinsic model of C40 material

参数	取值
初始屈服应力 A₁ / MPa	335
应变硬化系数 B₁ / MPa	1410.3
材料应变率强化参数 C₁	0.035
硬化指数 n	0.614
热软化指数 m	1.67

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表 3 冷却方式的温度与导热系数关系表

Table 3. Relationship between temperature and heat transfer coefficient for cooling methods

冷却方式	温度 T / ℃	导热系数 λ / （W·m⁻¹·K⁻¹）
空气	−20	0.0229
	−40	0.0214
	−60	0.0198
	−80	0.0182
	−100	0.0166
水	0	0.5557
	5	0.5677
	10	0.5787
	20	0.5980
	40	0.6284
液氮	−150	0.0502
	−170	0.0990
	−200	0.1508
	−220	0.2087
	−250	0.3670

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表 4 切削力仿真结果统计表

Table 4. Statistics of cutting force simulation results

冷却方式	F_x / N	F_y / N	F_z / N
干切削	4.1	0.14	2.5
低温风冷却	3.6	0.05	2.5
高压水冷却	3.5	0.08	2.4
液氮冷却	3.4	0.02	2.3
低温喷雾冷却	3.5	0.05	2.3

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表 5 烧结式金刚石串珠绳参数表

Table 5. Parameters of sintered diamond beaded ropes

参数	取值
串珠直径 d / mm	ϕ11.5
每米串珠个数 N / 个	40
磨粒粒度 / 目	40～50
绳长 l / m	2.95

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表 6 实验工件的组成成分和性能参数

Table 6. Composition and performance parameters of experimental workpieces

类型	型号	成分	抗压强度 σ / MPa
Ⅰ级钢筋	Q235	Fe、C、Mn、Si	235
混凝土	C40	水泥、水、砂、碎石	40

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表 7 串珠绳实验切削参数

Table 7. Experimental cutting parameters of beaded rope

实验组号	切削速度 v / (m·s⁻¹)	进给速度 v_f / (mm·min⁻¹)	张紧力 F / N
1	24	9	2100
2	26	9	2300
3	28	9	2500
4	24	12	2300
5	26	12	2500
6	28	12	2100
7	24	15	2500
8	26	15	2100
9	28	15	2300

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表 8 实测温度与仿真温度表

Table 8. Measured and simulated temperature table

冷却方式	切削区的最高温度 T / ℃		误差 ε / %
冷却方式	仿真值	实验值	误差 ε / %
干切削	880	847	3.90
低温喷雾冷却	560	532	5.26
高压水冷却	610	585	4.27

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