预应力淬硬磨削复合加工新工艺机理及全参数表面完整性研究

Based on the principle of prestress grinding and grinding hardening process, the research work presents a new integrated process, Pre-stressed Hardening Grinding (PSHG), which integrated the residual stress control, surface hardening and grinding process. The research work establish the interference model of stress, temperature and metallurgical physical coupling field in contact area in PSHG process, study and reveal the formation mechanism of surface integrity including residual stress, surface hardness, surface roughness and microstructure damage in PSHG process. For typical part machined by PSHG process, perform the experimental study on the application performance of friction and wear, fatigue and corrosion resistance. From all parameters range, evaluate and predict the surface integrity in PSHG process; establish and develop the all parameters surface integrity prediction model and system. Establish the optimization and matching method and criteria of process parameters of PSHG. Create the theory frame and the technical specification of PSHG process initially. The research work will provide the basis for practical development of PSHG process.

从抗疲劳制造与绿色制造的观念出发，融合预应力磨削与磨削淬硬技术原理，提出一种将残余应力控制、表面淬火及磨削加工三者集成于一体的预应力淬硬磨削新技术理论与方法。建立预应力淬硬磨削复合加工接触区应力、温度与冶金物理耦合场干涉模型，开展预应力淬硬磨削复合加工机理的理论与试验研究；揭示预应力淬硬磨削复合加工工件表面变质层的金相组织、残余应力、表面硬度、表面粗糙度及微结构损伤等表面完整性指标特征与形成机理；针对多种加工条件下预应力淬硬磨削复合加工后的典型零件，开展摩擦磨损、疲劳强度及耐腐蚀等性能的应用性能实验研究；从全参数角度综合评价和预测预应力淬硬磨削复合加工表面完整性指标，建立并开发预应力淬硬磨削复合加工表面完整性全参数预测模型与预报系统；实现工艺参数的优化匹配，初步建立预应力淬硬磨削复合加工新技术的理论框架和技术规范。为开发预应力淬硬磨削复合加工新工艺技术提供研究基础。

从抗疲劳制造与绿色制造的观念出发，融合预应力磨削与磨削淬硬技术原理，提出一种将残余应力控制、表面淬火及磨削加工三者集成于一体的预应力淬硬磨削新技术理论与方法。项目完成了全部工作计划，取得了预期研究成果，并完成了各项考核指标。建立了预应力淬硬磨削复合加工接触区应力、温度与冶金物理耦合场干涉模型，开展预应力淬硬磨削复合加工机理的理论与试验研究；揭示了预应力淬硬磨削复合加工工件表面变质层的金相组织、残余应力、表面硬度、表面粗糙度及微结构损伤等表面完整性指标特征与形成机理；针对多种加工条件下预应力淬硬磨削复合加工后的典型零件，开展摩擦磨损、接触疲劳强度等接触性能的应用性能实验研究；完成了预应力专用夹具设计与开发。从全参数角度实现了预应力淬硬磨削复合加工表面完整性指标的综合评价和预测，建立并开发了预应力淬硬磨削复合加工表面完整性全参数预测模型与预报系统；实现工艺参数的优化匹配，初步建立了预应力淬硬磨削复合加工新技术的理论框架和技术规范。为开发预应力淬硬磨削复合加工新工艺技术提供研究基础。