高效切割刀具耦合仿生设计理论与技术方法

In order to process new materials and modern high-performance materials, cutting tools need to improve cutting performance. On the basis of research on the biological characteristics of badger teeth, the project explores bionic design theories and techniques for efficient cutting tools. According to badger teeth structures, alignment and occlusion way, material properties, including teeth contours, kinematic characteristics, material composition, hierarchical structure, mechanical and tribological properties, we analyze the coupling mechanisms both structures and materials in the process of badger teeth cutting food, which show excellent features on low resistance，low power consumption and low wear. Based on the analysis on failure behavior of existing cutting tools, we intend to use the functional structure of the badger teeth to design and create three types of cutting tool samples used for gantry shear machine, cutting band saw and disk saw, respectively. These cutting tool samples which have different bionic structures possess different motion characteristics. The bionic structure parameters would be optimally designed by simulation methods. The cutting performance of the samples are tested and analyzed. The AlMgB14 ceramic coatings are coated on bionic cutting tool bases by mechanical alloying and plasma spraying technique. We explore the coupling effects and mechanisms both the bionic structure parameters and the coating microstructure properties for cutting tools, such as using orthogonal experimental design and regression forecasting method. This project develops theories and techniques of bionic coupling design for efficient cutting tools.

现代新型材料和高性能材料的加工对切割刀具性能提出了更高的要求。本项目以獾牙齿的生物学特性研究为切入点，探索高效切割刀具耦合仿生设计理论和技术方法。对獾牙齿结构、排列和咬合方式、材料特性，包括齿形轮廓、运动学特征、材料成分、构成方式、机械性能、摩擦学特性等进行研究，分析其在切割食物过程中低阻力、低功耗和低磨损特性以及结构和材料耦合作用机理；在分析现有切割刀具失效行为的基础上，以獾牙齿不同功能结构为原型，设计应用于龙门剪切机刀片、切割带锯、圆盘锯三种具有不同运动特征的切割刀具仿生结构，采用模拟仿真方法对仿生结构进行优化设计；制备仿生切割刀具样品，采用机械合金化和等离子喷涂技术在样品上制备AlMgB14陶瓷涂层，对样品切割性能进行测试和分析；采用正交试验设计、回归预测等方法，研究仿生结构参数和涂层组织结构对切割刀具性能的耦合作用规律和影响机理，并形成系统的高效切割刀具耦合仿生设计理论与技术方法。

本项目针对切割部件和挖掘机斗齿在工作过程中所面临的效率和寿命问题，开展仿生切割部件的设计理论和方法研究。通过对狗獾牙齿的微观结构、力学性能及组成成分进行分析，研究了狗獾牙齿釉质层和本质层硬度的差异。通过咬合力传感器测量狗獾咬合时的咬合曲线，研究了狗獾在咬合物体时的咬合力大小和特点。基于计算机断层扫描和三维扫描技术，构建了狗獾头部和爪趾模型，并进行优化。基于计算机视觉技术和描点法，提取了狗獾犬齿和爪趾的特征曲线，并进行了拟合。通过三维计算机软件，对所研究部件进行仿生设计，进行静力学分析，并对所设计部件进行了再优化。对所设计部件进行了加工，利用试验优化方法进行试验台切割与挖掘试验，得到了所设计仿生部件与市售对比部件的切割和挖掘参数。利用仿真模拟对锯切削过程中的温度场和切屑的Mises 应力进行了分析，并对仿生锯齿对切屑的影响进行了探讨。对被切材料的断面形貌进行了分析，最终得到了适用于不同切削速度条件下的齿形参数。形成了系统的高效切割刀具耦合仿生设计理论与技术方法。利用等离子表面强化技术，将Ni60A-wt.%AlMgB14复合粉末喷涂于M42高速钢表面，通过磨损试验，探索了其磨损性能与机理。耐磨涂层能够有效降低试样的磨损率和摩擦因数。