Effect of Ultrasonic Rolling Process Parameters on Surface Integrity and Impact Performance of 45 Steel
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摘要:
设计了以静压力（400,800,1 200 N）、振幅（3,5,7 μm）、滚压道次（1,2,3）等超声滚压工艺参数为变量,表面粗糙度、残余应力、显微硬度和冲击吸收功为响应的的正交试验,研究了超声滚压参数对45钢表面完整性与冲击性能的影响。结果表明：随着静压力和振幅增加,试样的表面粗糙度增大,滚压道次影响较小；随静压力、振幅、滚压道次增加,试样的表面残余压应力略有增大；随着静压力与振幅增加,硬化层深度增大,随着滚压道次增加,硬化层深度先减小后增大；随着静压力和振幅增加,冲击吸收功先减小后增大,随滚压道次增加,冲击吸收功增大；对表面粗糙度、表面残余应力、硬化层深度和冲击吸收功影响最大的因素分别为振幅、静压力、静压力和滚压道次；最佳超声滚压工艺参数为静压力400 N、振幅7 μm、滚压3次,此时试样灰色关联度最大,表面完整性和冲击性能较好。
Abstract:Ultrasonic rolling orthogonal tests were designed with static pressure (400, 800, 1 200 N), amplitude (3, 5, 7 μm), rolling pass (1, 2, 3) as variables, surface roughness, residual stress, microhardness and impact absorption work as response. The effect of ultrasonic rolling parameters on the surface integrity and impact properties of 45 steel was studied. The results show that with the increase of static pressure and amplitude, the surface roughness of the sample increased,and the effect of rolling pass was small. With the increase of static pressure, amplitude and rolling pass, the surface residual compressive stress of the sample increased slightly. The depth of hardened layer increased with the increase of static pressure and amplitude, and first decreased and then increased with the increase of rolling pass. The impact absorption work first decreased and then increased with the increase of static pressure and amplitude, and increased with the increase of rolling pass. The most influential factors of surface roughness, surface residual stress, hardened layer depth and impact absorption work were amplitude, static pressure, static pressure and rolling pass, respectively. The optimum ultrasonic rolling parameters were as follows: static pressure of 400 N, amplitude of 7 μm, rolling pass of 3. Under the eptimal parameters, the gray correlation degree of the sample was the largest, and the surface integrity and impact performance were good.
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图 1 试样表面粗糙度、硬化层深度、表面残余应力和冲击吸收功随工艺参数的变化趋势
Figure 1. Variation trend diagram of surface roughness (a), hardened layer depth (b), surface residual stress (c) and impact absorption energy (d) of sample with process parameters
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图 2 不同工艺参数超声滚压后试样的残余应力和显微硬度沿层深分布
Figure 2. Residual stress (a) and microhardness distribution (b) along layer depth of samples after ultrasonic rolling with different process parameters
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图 3 不同工艺参数超声滚压后试样的显微组织
Figure 3. Microstructure of samples after ultrasonic rolling with different process parameters
表 1 正交试验因素和水平
Table 1 Orthogonal experimental factors and levels
水平 静压力/N 振幅/μm 滚压道次 1 400 3 1 2 800 5 2 3 1 200 7 3 
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表 2 正交试验结果
Table 2 Orthogonal experimental result
试样编号 静压力/N 振幅/μm 滚压道次 表面粗糙度/μm 表面残余应力/MPa 硬化层深度/μm 冲击吸收功/J 1 400 3 1 0.13 -513.9 130 13.3 2 400 5 2 0.07 -509.3 110 11.7 3 400 7 3 0.13 -512.0 190 16.3 4 800 3 2 0.10 -523.2 190 12.0 5 800 5 3 0.06 -556.4 150 14.7 6 800 7 1 0.08 -557.2 270 10.3 7 1 200 3 3 0.09 -549.5 270 12.7 8 1 200 5 1 0.09 -521.0 350 10.7 9 1 200 7 2 0.16 -570.7 230 13.7
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表 3 性能方差分析
Table 3 Variance analysis of performance
指标 方差来源 方差分析平方和 自由度 均方 F 显著性 表面粗糙度 静压力 0.002 064 2 0.001 032 振幅 0.003 327 2 0.001 664 2.128 23 显著 滚压道次 0.000 517 2 0.000 259 误差 0.002 109 2 0.001 054 总误差 0.004 69 6 0.000 782 表面残余应力 静压力 2 401.016 2 1 200.508 3.586 775 显著 振幅 630.139 4 2 315.069 7 滚压道次 112.366 8 2 56.183 39 误差 1 265.718 2 632.859 总误差 2 008.224 6 334.704 硬化层深度 静压力 29 600 2 14 800 4.826 087 显著 振幅 1 866.667 2 933.333 3 滚压道次 8 266.667 2 4 133.333 误差 8 266.667 2 4 133.333 总误差 18 400 6 3 066.667 冲击断裂吸收功 静压力 4.174 183 2 2.087 091 振幅 1.805 531 2 0.902 765 滚压道次 15.137 38 2 7.568 691 3.244 772 显著 误差 8.015 768 2 4.007 884 总误差 13.995 48 6 2.332 58
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表 4 线性组合系数及权重结果
Table 4 Linear combination coefficient and weight results
名称 主成分1 主成分2 综合得分系数 权重/% 特征根 1.872 1.240 - - 方差解释率/% 46.79 30.99 - - 静压力 0.647 7 0.260 1 0.493 3 25.61 表面残余应力 0.565 6 0.458 9 0.523 1 27.16 冲击断裂吸收功 0.402 7 0.576 9 0.472 1 24.52 表面粗糙度 0.313 7 0.623 7 0.437 2 22.71
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