Research on the nanometric machining of a single crystal nickel via molecular dynamics simulation

Molecular dynamics simulations are employed to study the nanometric machining process of single crystal nickel. Atoms from different machining zones had different atomic crystal structures owing to the differences in the actions of the cutting tool. The stacking fault tetrahedral was formed by a series of dislocation reactions, and it maintained the stable structure after the dislocation reactions. In addition, evidence of crystal transition and recovery was found by analyzing the number variations in different types of atoms in the primary shear zone, amorphous region, and crystalline region. The effects of machining speed on the cutting force, chip and subsurface defects, and temperature of the contact zone between the tool and workpiece were investigated. The results suggest that higher the machining speed, larger is the cutting force. The degree of amorphousness of chip atoms and the depth and extent of subsurface defects increase with the machining speed. The average friction coefficient first decreases and then increases with the machining speed because of the temperature difference between the chip and machining surface.     

切削区温度分布研究

金属切削加工中,切削热与切削温度是一重要的物理现象,切削温度及其分布直接影响刀具磨损和工件的加工精度及表面质量.本文通过分析切削力和刀—屑接触长度的计算,建立了刀—屑接触区的正应力与剪应力的分布计算模型,采用有限元法对稳态切削过程中切削温度分布进行了计算,得到了切削区切削温度的分布情况.     

AlCrSiN涂层刀具干车削Ti-6Al-4V钛合金的切削性能研究

使用未涂层的和AlCrSiN涂层的硬质合金车刀片以3种切削速度干式车削Ti-6Al-4V钛合金.研究发现AlCrSiN涂层刀片的切削寿命在各切削速度下都超过无涂层刀片,而切削力、切削温度和工件表面粗糙度3项指标均低于无涂层刀具,说明AlCrSiN涂层能够有效地保护基体从而维持刀具的锋利度.2种刀具在切削过程中均出现切削...     

微织构球头铣刀加工钛合金的有限元仿真

为了研究微织构对球头铣刀切削性能的影响与表面微织构的抗磨减摩性能,通过分析微织构的设计理论,对微织构刀具和普通刀具切削钛合金TC4进行了三维动态切削仿真,对比分析了两种刀具在切削过程中切削力、切削温度及刀具磨损的变化.结果表明,在干式切削条件下,微织构刀具在切削过程中切削力降低了16%,切削温度降低了13%,磨损深度值是普通刀具的25%,但刀具变形变大.微织构在球头铣刀切削过程中能够减小切削力,降低切削温度,减小刀具前刀面的磨损,延长刀具寿命,但可能会影响加工精度.     

速度效应对淬硬钢最小切削厚度的影响

塑性材料加工中,存在一个最小切削厚度,当切削加工中实际有效切削厚度小于工件材料的最小切削厚度时,将造成刀具与工件无法正常切削,而主要以滑擦为主,此时加工精度很难保证,确定材料的最小切削厚度对提高工件的加工质量及精度具有重要意义.针对以上问题以淬硬钢Cr12Mo V材料为研究对象,提供了一种确定工件材料最小切削厚度的试验方法,并通过提供的试验方法,确定了淬硬钢Cr12Mo V(58 HRC)不同切削速度下的最小切削厚度值,试验结果表明:在所选的速度范围内,热软化效应对淬硬钢Cr12Mo V(58 HRC)成屑机制的影响大于应变率效应的影响,淬硬钢Cr12Mo V(58 HRC)最小切削厚度值的确定,为汽车覆盖件模具精加工余量的选取提供了理论依据.     

ZrO_2陶瓷激光加热辅助切削加工技术

为了解决高强度、高脆性氧化锆(ZrO2)陶瓷材料加工困题的问题,对激光加热辅助切削(Laser-assisted machining,LAM)ZrO2陶瓷加工技术进行了研究。建立了热传递的三维模型,并采用ANSYS软件进行了温度场有限元仿真。搭建了切削试验系统并进行了加工试验。试验采用Nd:YAG激光器进行连续加热,红外线测温仪测量表面温度,压电式测力仪在线测量切削力,并对切屑形状、刀具磨损状态和加工质量做了研究。结果表明:相对传统切削加工技术,LAM加工技术能够有效地减小切削力,减缓刀具磨损和改善加工表面质量。     

柱形棒铣刀铣削锥形螺杆的切削形面产生机理

为了采用柱形棒铣刀实现几何形状较复杂部件螺杆挤出副的高精度铣削加工,根据刀具与工件的空间几何关系,利用柱形刀具截面与工件的实际切削点建立数学模型.经过理论分析推导出在开槽和精加工时由柱形棒铣刀所铣削的实际螺旋形面,说明了其为近似倒锥形而非圆柱形,进而提出了由反求计算校正铣刀摆角的方法,并通过实际试切实验验证了理论分析的正确性.该方法可用于实际切削加工前的计算,以正确确定刀具摆角,有效提高锥形螺杆曲面的加工精度和效率.     

超声振动铣削运动学及其对切削力的影响

为了改善微细铣削的加工条件,研究了利用超声振动辅助微细铣削对切削力的影响.基于对刀具轨迹的运动学分析,讨论了利用超声振动辅助微细铣削时实现刀具-工件分离的必要参数条件,以2A12为实验工件材料,通过超声振子带动工件沿进给方向进行超声振动,并采用多组参数进行了铣槽实验.实验结果分析表明,采用合理的切削及振动参数配比,进给方向超声振动辅助微细铣削可改变刀具-工件的相对运动方式,实现分离型断续铣削,可获得近似脉冲状切削力并有效减小切削力的均值,选择合理的振幅可明显减小进给方向切削分力峰值.     

基于Deform-3D的镍基高温合金残余应力仿真分析

GH4169镍基高温合金应用广泛,但是属于难以加工的材料,而且已加工表面的残余应力很容易导致工件变形,从而影响工件的加工质量。应用Deform 3D软件,研究了不同切削用量下残余应力的变化规律。研究结果表明,切削速度的变化对表面残余应力的影响甚小|背吃刀量和进给量增大,表面残余应力随之增大|随着切削用量的增加,工件内部残余应力亦随之增加。     

多刀具纳米切削铜过程研究

运用分子动力学模拟技术建立多刀具纳米切削铜模型,工件原子间相互作用力采用eam势计算,工件与刀具原子间相互作用力采用morse势计算,刀具原子间相互作用力采用tersoff势计算.通过分析切削过程中瞬间原子图像、切削力、能量、温度,发现多刀具纳米切削过程并不等同于单把刀具多次走刀,刀具之间相互干涉会影响切削力的变化.结果显示多刀具与单把刀具切削比较,切削力在一定程度内会变小,工件的温度相对较高,最终会影响切削效果.     

一种基于FTS车削的微切削力模型

机械加工中的切削力模型建立对于研究工件表面形貌成型,探究切削理论有着深远的意义。在微切削加工领域,伺服车削通常用来加工自由曲面,但是考虑到尺寸效应,传统宏观领域的切削力模型无法真实地描述切削过程。针对微切削加工领域,提出了一种切削力模型,模型充分考虑了最小未成型切屑厚度,刀具切削刃钝圆以及工件对后刀面回弹引起的摩擦力。由于切削深度不同,所对应的切削原理也不同,将切削过程分为多个区域建模。当刀具切入工件后,随着切屑厚度的减小,切屑在前刀面分别经历宏观剪切、大负前角切削以及耕梨过程,而同时工件未切下的部分在后刀面的进一步作用下形成已加工表面,对应上述过程,将分为4个区域建模。最后,基于自主设计的能够精确测量两个方向切削力的快刀伺服装置(DFT-FTS)设计实验。     

正交金属切削温度场有限元分析

目的研究正交金属切削系统温度分布规律,建立其温度场有限元分析模型. 方法给出切削力、剪切角等易测量实验数据,并利用热传导有限元法计算多种切削条件下系统温度分布. 结果计算结果与经典实验结果吻合较好,并给出了切削参数对切削温度的影响. 结论该有限元分析模型设计合理,是研究正交金属切削系统温度分布规律的可行方案.     

MD simulation of nanometric cutting of copper with and without water lubrication

Three-dimensional molecular dynamics(MD)simulation was carried out to understand the mechanism of water lubrication in nanometric cutting.The water-lubricated cutting was compared with the dry cutting process in terms of lattice deformation,cutting force,heat and pressure distribution,and machined surface integrity.It was found that water molecules effectively reduce the friction between the tool and workpiece,the heat in the cutting zone and the pressure being generated on the tool surface,thus leading to prolonged tool life.Water molecules also enlarged the pressure-affected area,which decreased the roughness of the machined surface.     

高速切削刀具的分析研究

介绍高速切削技术在机械加工上的优势,通过高速切削加工对刀具材料、刀具结构、几何角度和安全性的要求分析影响刀具寿命的因素,得出高速加工切削力、切削温度、刀具寿命、表面粗糙度及切削稳定性影响规律,对今后的实践加工具有参考和借鉴作用.     

Temperature distribution in the tool-chip-workpiece system during the orthogonal cutting process

The temperature distribution in the tool, chip and workpiece was studied during the orthogonal cuttingprocess Under several different cutting conditions. The temperature distribution is calculated by the finite differencemethod. and the variation of the material properties with temperature was taken was taken into account The results obtained arecoincident with both previous published results and experimental measurements.     

基于ABAQUS的钛合金稳态切削模拟

本文基于ABAQUS软件的Johnson-Cook材料模型以及ALE网格划分技术对钛合金稳态切削加工过程进行了有限元模拟,并研究了钛合金的切屑成型过程、切削层的塑形应变以及工件温度的分布,从切屑形状上看,模拟结果与试验结果基本吻合。在此基础上分析了不同切削前角、切削深度和切削速度等参数对切削力的影响,发现在一定范围内适当增大切削前角或减小切削深度有利于切削的进行,此外切削速度的变化在一定范围内对切削力影响较小。     

Minimum Normal Force Principle Based Quantitive Optimizationof Clamping Forces for Thin Walled Part

Based on the stability criteria of workpiece-fixture system, quantitative optimization of clamping forces during precise machining process for thin walled part is studied considering the contact condition between wokpiece and locator, the contact mechanical model is achieved ,which is further been used to calculate the entire passive forces acting on the statically undetermined workpiece by means of the force screw theory as well as minimum norm force principle. Furthermore, a new methodology to optimize clamping forces is put forward, on the criteria of keeping the stability of workpiece during cutting process. By this way, the intensity of clamping forces is decreased dramatically, which will be most beneficial for improving the machining quality of thin-walled parts. Finally, a case study is used to support and validate the proposed model.     

机械加工精度误差及对策探讨

在机械加工中,由机床、夹具、刀具和工件组成的工艺系统,会有各种各样的误差产生,并影响了工件的加工精度。本文以教学实践经验为基础,简要介绍了机械加工精度的基本知识,进而对影响机械加工精度的因素进行了分析,最后对如何减少各种因素对加工精度的影响提出了相应的对策和建议。     

Optimization of material removal strategy in milling of thin-walled parts

The optimal material removal strategy can improve a geometric accuracy and surface quality of thin-walled parts such as turbine blades and blisks in high-speed ball end milling.The dominant conception in the material removal represents the persistence of the workpiece cutting stiffness in operation to advance the machining accuracy and machining efficiency.On the basis of theoretical models of cutting stiffness and deformation,finite element method (FEM) is applied to calculate the virtual displacements of the thin-walled part under given virtual loads at the nodes of the discrete surface.With the reference of deformation distribution of the thin-walled part,the milling material removal strategy is optimized to make the best of bracing ability of still uncut material.This material removal method is summarized as the lower stiffness region removed firstly and the higher stiffness region removed next.Analytical and experimental results show the availability,which has been verified by the blade machining test in this work,for thin-walled parts to reduce cutting deformation and meliorate machining quality.     

Web模式切削数据库与专家系统研究

在金属切削过程中,刀具牌号和切削用量参数的合理选择对降低加工成本、提高生产效率具有重大意义.主要对切削数据库与专家系统进行开发,该系统基于Web模式采用ASP（active server page）技术开发,可根据实际加工条件合理推荐刀具和切削用量参数,并具有刀具对照查询和故障诊断等功能.系统可网络访问,满足企业多车间、跨地区资源共享.采用该系统可提高企业经济效益.