深水环境下金刚石串珠绳切割钢基材料切削及磨损特性研究

Because the harsh test conditions and high cost of cutting steel-based materials using diamond wires in deep sea environment, the related basic technology research lags for behind the application. Aiming at solving the problems of low cutting efficiency and short service life of diamond beaded rope in deep water, the project will carry out the following work: establishing a 3D surface topography model of diamond beads, and exploring a numeral characterization method for sintered beads, and establishing the mechanical model of grinding interface between the abrasive grains and the bond, and simulating the cutting process to realize the evaluation of cutting performance; based on the cutting experiment in deep water, revealing the cutting mechanism and wear mechanism from the point of view of microscopic conditions; deeply researching the dynamic characteristics of string bead wire in deepwater conditions and putting forward an effective strategy of vibration suppression; revealing the effects rules of cutting material, beads structure, vibration of beaded rope and cutting parameters on cutting efficiency and life and optimizing their parameters to create an efficient, reliable plan strategy of cutting process and life prediction method of string bead wire. The research is still a blank in China, the research work will provide a theoretical and technical support of the application development of the string bead wire and help develop a new type of string bead wore for the deep-sea engineering operation.

由于深水环境中金刚石串珠绳切割钢基材料试验条件及成本限制，其相关基础技术研究远远落后于应用。针对金刚石串珠绳深水环境中切割钢基材料切削效率低及使用寿命较短、且无法准确预测的难题，本项目将进行串珠表面形貌检测及三维形貌建模，实现烧结式串珠表面三维形貌的数值表征，建立磨粒与结合剂之间界面力学模型，并进行切削过程仿真研究，实现利用表面形貌对切削性能的评价；结合模拟深水环境中的切割实验，从微观角度揭示该工况下的切削和磨损特性；深入研究深水工况下串珠绳振动动力学特性，提出抑制振动的有效策略；揭示深水作业时切割材料、串珠结构、切削参数、串珠绳振动对切削效率、串珠绳寿命的影响规律，优化切削参数，创建一种高效、可靠的水下切削工艺规划和寿命预测方法。本项目研究内容在国内尚属空白，研究工作将为推动串珠绳切割技术应用领域的拓展提供理论和技术支持，同时可指导适合深海工程作业的新型串珠绳的开发。

本项目对金刚石串珠表面形貌和磨粒形态进行了观察、测量与分析，建立了串珠表面的三维形貌，进行了单颗金刚石磨粒和金刚石串珠切割钢基材料、钢筋混凝土材料的仿真研究，并在模拟深水环境下进行了金刚石串珠的切削实验，结合切屑形态，深入研究了金刚石串珠切割钢基材料的磨削和磨损特性。建立了单颗金刚石磨粒与胎体结合的力学模型，结合界面力学，进行了仿真分析，对金刚石串珠切割钢基材料、钢筋混凝土材料的切削性能进行了研究。研究了金刚石串珠绳切削过程的振动特性，从驱动轮平稳运行和非平稳运行两种状态出发，研究了金刚石串珠绳与驱动轮之间的力矩传递特性，明确了振动对串珠绳切削性能及磨损特性的影响，提出了一种将振动参量控制在有利于切割作业范围内的有效方法。建立了金刚石串珠绳深水切割钢基材料寿命预测方法，并规划了切削工艺参数。发表论文10篇，其中SCI收录4篇，EI收录6篇；申请国家发明专利9项，授权9项；培养硕士毕业生10人，博士生1人，其中硕士研究生有1人到国外高校交流3个月。本项目的研究成果为金刚石磨粒切削性能、磨损性能、切屑形貌及疲劳寿命的进一步研究奠定了基础，也为金刚石串珠绳切割技术在海洋工程、废弃核设施解体等特殊领域的应用提供技术指导与支持。