引用本文:邱天,言兰,王福增,谢鸿,税妍,张涛,姜峰.材料去除过程中Rehbinder效应的研究进展[J].中国表面工程,2024,37(1):59~74
QIU Tian,YAN Lan,WANG Fuzeng,XIE Hong,SHUI Yan,ZHANG Tao,JIANG Feng.Research Advances of Rehbinder Effect in Material Removal Process[J].China Surface Engineering,2024,37(1):59~74
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材料去除过程中Rehbinder效应的研究进展
邱天1,2, 言兰2,3, 王福增1,2, 谢鸿4, 税妍4, 张涛1,2, 姜峰1,2
1.华侨大学制造工程研究院 厦门 361021;2.高性能工具全国重点实验室 厦门 361021;3.华侨大学机电及自动化学院 厦门 361021;4.东方汽轮机有限公司 德阳 618000
摘要:
精密机械加工过程中,利用 Rehbinder 效应对工件表面特性的影响,可以更好地控制零件表面质量。不同工程材料的 Rehbinder 效应的微观表现形式有所差异,但宏观结果都是降低工件表面硬度,使材料去除过程更容易进行。回顾了 Rehbinder 效应概念的提出和发展过程并对其内涵和应用范围进行了阐述,为加工过程中的材料去除方法提供思路,对材料表面完整性的形成具有指导意义。列举了近年来科研人员对 Rehbinder 效应的相关研究成果,分析对比其在硬脆材料和塑性材料加工过程中的表现形式和微观作用机理,总结 Rehbinder 效应的影响因素,如极性分子的吸附活性、工件材料的晶粒尺寸等。揭示了 Rehbinder 效应中极性分子的吸附作用,以及吸附作用后的扩散、位错和间隙三种促进机制,并综述离散元法、有限元法和分子动力学等数值仿真方法对宏观尺度和微观尺度 Rehbinder 效应机理的研究。Rehbinder 效应可以看作是一种对加工表面的改性机制,研究 Rehbinder 效应作用下的表面活性剂与被加工表面的匹配机制是提高材料表面完整性的关键,对推动精密制造工艺的发展有重要意义。
关键词:  材料去除  Rehbinder 效应  机械加工  数值仿真
DOI:10.11933/j.issn.1007-9289.20220227001
分类号:TH16;TG506
基金项目:国家重点研发计划(2023YFB3407200)
Research Advances of Rehbinder Effect in Material Removal Process
QIU Tian1,2, YAN Lan2,3, WANG Fuzeng1,2, XIE Hong4, SHUI Yan4, ZHANG Tao1,2, JIANG Feng1,2
1.Institute of Manufacturing Engineering, Huaqiao University, Xiamen 361021 , China;2.State Key Laboratory of High Performance Tools, Xiamen 361021 , China;3.College of Mechanical Engineering and Automation, Huaqiao University, Xiamen 361021 , China;4.Dongfang Turbine Co., Ltd., Deyang 618000 , China
Abstract:
The Rehbinder effect on the surface characteristics of the workpiece can be utilized to enable better control of the surface quality of the parts in precision machining processes. The microscopic manifestation of the Rehbinder effect varies among different engineering materials, but the macroscopic result is the reduction of the surface hardness of the workpiece, making the material removal process easier to proceed. A systematic review of the conceptualization and development process of the Rehbinder effect is presented, and its expressions and applications are elaborated, which can provide a way for the material removal method during processing and have a guiding significance for the formation of material surface integrity. The relevant findings of researchers on the Rehbinder effect in recent years are listed, both brittle materials and plastic materials, can be removed easily in machining process by utilizing the Rehbinder effect. However, the expressions of the Rehbinder effect are different for different materials. For polycrystalline hard and brittle materials such as rocks, surface active additives adsorbed on the surface of the workpiece enter the micro-cracks and continue to penetrate when there are micro-cracks on the material surface. Surface active additives can promote the expansion of micro-cracks to accelerate the mechanical damage of the structure. For single crystal hard and brittle materials such as silicon carbide and sapphire, surface active additives adsorbed on the material surface undergo a chemical reaction with the workpiece. The lower hardness of the reaction products makes the material easier to machine. For plastic materials such as metals, the role of the Rehbinder effect is also related to the grain size and dislocation density of the material. The mechanism of the Rehbinder effect can be demonstrated in the macroscopic and microscopic performance in the machining process. The factors that affect the Rehbinder effect such as the adsorption activity of polar molecules and the grain size of the workpiece material are summarized. The Rehbinder effect occurs on the premise that polar molecules adsorb on the surface of the workpiece. The diffusion, dislocation, and interstitial mechanisms generated by the Rehbinder effect reduce the surface strength of the workpiece further. Related mechanisms of the Rehbinder effect evaluated by numerical simulation methods are reviewed. The discrete element method can be used to analyze the mechanical processes in rocks, but there are limitations in the analysis of the Rehbinder effect. The finite element method is an important tool for simulating the deformation and removal processes of plastic materials. Some scholars have investigated the Rehbinder effect through the finite element method by modifying the fracture energy, elastic modulus or yield stress of different phases/grains in the ink-affected layer, and finding changes in the chip morphology. Because of the difficulty in modeling the adsorption of the surface active additives on the surface of materials and the diffusion in cracks, most of the current studies have simulated the adsorption by the surface modification of the material and have not involved penetration and diffusion. Molecular dynamics simulations can be adopted to evaluate the mechanism of the Rehbinder effect at smaller scales. The results show that the water molecule can improve the surface quality in precision and ultra-precision machining with a small amount of material removal as a kind of polar molecule, which is a manifestation of the Rehbinder effect. The combination of the experimental phenomena and simulation results can be effectively explained for the mechanism of the Rehbinder effect. The Rehbinder effect can be regarded as a modification mechanism for the machined surface. The study of the matching mechanism between surfactant and machined surface under the action of Rehbinder effect is the key to improving the material surface integrity, which is significant for promoting the development of precision manufacturing process.
Key words:  material removal  Rehbinder effect  machining  numerical simulation
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