刀具几何参数对钛合金TB6切削力的影响研究

切削力是金属切削过程的重要物理参数之一,直接影响到工件质量、刀具寿命、机床功率消耗,是分析设计机床、刀具、夹具的重要因素。本文使用田口方法,以切削力为指标,对刀具几何参数中的前角、后角、螺旋角进行了分析优化。采用L9(34)正交试验表,设计了不同几何参数的刀具,对每组参数组合进行了切削试验,得到了在相同切削条件下的切削力。利用信号与干扰比分析、方差分析研究了不同几何参数对切削力的影响,获得了切削力最小情况下的刀具的最优几何参数组合。最后,使用优化后的几何参数实际验证了该方法的有效性。     

加工Ti-6Al-4V硬质合金立铣刀的几何参数优化仿真研究

Ti-6Al-4V属于难加工材料,具有热导率低、加工硬化现象严重和弹性模量低等特点,而硬质合金刀具对该材料具有较好的加工性能。刀具的几何参数对刀具上的应力、切削力、切削温度和加工表面质量有重要影响,故可以通过优化刀具几何参数来获得刀具的最优切削性能。建立三维铣削有限元模型,经过切削仿真试验分析硬质合金平头立铣刀的螺旋角、径向前角及径向后角对切削过程中的最大正应力、切削力及切削温度的影响,实现刀具几何参数的优化设计。     

车削ZL109铝合金PCD刀具参数对切削性能影响研究

利用材料试验机和SHPB装置对ZL109进行准静态和动态冲击压缩实验,确定了ZL109铝合金的本构模型参数。采用单因素试验法,模拟刀具前角、后角和刀尖圆弧半径对切削力和刀尖温度的影响。结果表明:刀尖圆弧半径对X和Y方向切削力影响最大,而前角对Z方向切削力影响最大,后角对刀尖温度的影响最大。通过正交试验法和极差分析可知,当刀具几何参数选择为前角γ0=0°,后角α0=7°,刀尖圆弧半径r=0.4mm时,PCD车刀切削ZL109铝合金时刀具的切削性能最优。     

车刀几何参数对高温合金切削力的影响规律研究

为了降低高温合金切削过程的切削力,采用有限元仿真与切削试验相结合的方法,研究了车刀的几何参数(前角、后角和刀尖圆弧半径)对高温合金切削力的影响规律;试验发现:在几何参数的研究范围内,随着刀具前角、后角和刀尖圆弧半径的增大,刀具切削力均呈现逐渐减小的趋势;由此获得切削力最小时的车刀几何参数:前角约4°,后角约14°,刀尖圆弧半径为1. 2mm。     

PCD刀具几何参数对铝合金加工表面粗糙度的影响

文中研究了PCD刀具在不同的刀具几何参数下车削铝合金的加工表面粗糙度.分别改变刀具的前角、后角和刀尖圆弧半径3个几何参数做单因素切削试验,试验后利用表面轮廓仪测量工件的表面粗糙度,最后分析刀具几何参数对加工表面粗糙度的影响.     

基于AdvantEdge仿真的刀具几何参数对钛合金Ti6Al4V切削力的影响研究

利用切削仿真软件Advant Edge对高速切削Ti6Al4V切削过程进行有限元模拟,研究了切削速度为200m/min、切削深度为0.085mm时刀具几何参数(前角γ_o、后角α_o、钝圆半径r_ε)对切削力的影响。通过分析计算求得切削力随刀具几何参数变化的一阶响应面数学模型,实现了利用刀具几何参数对切削力的预测,并通过误差计算和方差分析证明了预测模型的有效性。研究发现,在给定的参数变化范围内,刀具几何参数对_影响作用的大小顺序为前角γ_o钝圆半径r_ε后角α_o;对F_z影响作用的大小顺序为钝圆半径rε前角γ_o后角α_o。     

刀具几何参数对高速铣削SiCp/Al复合材料温度的影响研究

研究了PCD刀具高速铣削铝基复合材料时刀具几何参数对切削温度的影响。利用A baqus软件,对PCD刀具高速铣削SiCp/Al复合材料薄壁件进行仿真模拟。刀具回转直径为10 mm,切削线速度为300 m/min,改变刀具的前角和后角仿真出铣削时刀具和工件的温度场。通过对比数据,得出刀具角度变化对切削温度的影响规律,从而为实际加工时刀具几何参数的选择提供依据。     

刀具几何参数对钛合金Ti6Al4V切削加工的影响

针对钛合金切削过程中刀具易磨损的问题,深入研究了对刀具几何参数对钛合金Ti6A14V切削过程的影响.将正交切削数值模拟与试验相结合,研究了高速切削Ti6A14V过程中刀具几何参数(前角、后角、刀尖圆弧半径)对切削力的影响规律,同时,也研究了刀具几何参数对锯齿状切屑形成的影响规律.     

刀具材料及角度对7075-T6铝合金切削力的影响仿真

为了提高7075-T6铝合金的切削效率,采用单因素试验法基于ABAQUS软件分析不同刀具材料及刀具几何参数对切削力的影响。试验结果表明：使用YG8刀具切削加工7075-T6铝合金时受到的切削力最小;随着刀具前角的不断增大,切削力显著降低;随着刀具后角的不断增大,水平切削力的下降相对较缓,但垂直切削力显著降低。     

PCD刀具超声振动车削SiC_p/Al复合材料时的切削力特性研究

用PCD刀具对SiCp/Al复合材料进行了超声振动车削与普通车削的对比试验 ,探讨了切削速度、进给量和切深三种切削参数在两种切削状态下对切削力的影响规律 ,得出了超声振动车削SiCp/Al复合材料的主切削力经验公式。     

聚晶金刚石刀具的断屑槽尺寸参数设计

为解决聚晶金刚石(PCD)刀具在铝合金材料切削过程中的切屑缠绕问题,在PCD刀具的前刀面上设计了断屑槽.通过对切屑受力过程和断屑槽断屑机理的分析、切削几何关系的推导和有限元切削仿真实验,提取了5个PCD刀具断屑槽参数,即棱带宽度、倾角、反屑角、槽宽和反屑面转角.建立了PCD刀具断屑槽棱带宽度和反屑角的计算公式;改进了槽...     

Machinability aspects concerning micro-turning of PA66-GF30-reinforced polyamide

This paper aims to study the behavior of machining forces and machined surface finish when micro-turning PA66-GF30-reinforced polyamide with various tool materials under distinct cutting conditions. The performance of polycrystalline diamond (PCD), CVD diamond coated carbide and plain cemented carbide tools (K15-KF and K15) were investigated in addition to the influence of feed rate on cutting forces, surface roughness and chip formation. The results indicated that the radial force was the highest force component because of the reduction in the effective cutting edge angle. Moreover, the cutting force increased almost linearly with feed, whereas the feed and radial forces remained unaltered. The cutting tools possessing lower edge radius promoted lower surface finish and turning forces, i.e., the best results were provided by the PCD tool, followed by the uncoated carbide inserts and finally by the CVD diamond-coated carbide tool.     

适用于多种材料阵列微槽加工的聚晶金刚石铣槽刀制备

结合金刚石飞切刀具和锯片,设计了具有特定形状、尺寸和角度参数的铣槽刀,并采用电火花线切割加工方法制造出了PCD铣槽刀;利用自制PCD铣槽刀进行微细铣削试验,制备出了加工质量良好的典型阵列微槽结构。     

The performance of PCD tools in high-speed milling of Ti6Al4V

Tool performance of conventional tools is poor and a major constraint when used in milling titanium alloys at elevated cutting speeds. At these high cutting speeds, the chemical and mechanical properties of Ti6Al4V cause complex wear mechanisms. In this paper, a fine-grain polycrystalline diamond (PCD) end mill tool was tested, and its wear behavior was studied. The performance of the PCD tool has been investigated in terms of tool life, cutting forces, and surface roughness. The PCD tool yielded longer tool life than a coated carbide tool at cutting speeds above 100?m/min. A slower wear progression was found with an increase in cutting speeds, whereas the norm is an exponential increase in tool wear at elevated speeds. Observations based on scanning electron microscope (SEM) and energy dispersive spectroscopy (EDAX) analysis suggest that adhesion of the workpiece is the wear main type, after which degradation of the tools accelerates probable due to the combined effect of high temperature degradation coupled with abrasion.     

PCD刀具连续切削花岗岩的性能研究

用三种不同晶粒尺寸的自制PCD刀具,在三种切削速度下进行了花岗岩的湿式连续切削试验。对刀具前、后刀面的显微形貌特征进行了观测,分析了刀具失效机理,比较了不同晶粒尺寸及不同切削条件下刀具的切削寿命。对刀具后刀面磨损的测量结果表明,在三种切削速度下,粗颗粒PCD刀具显示出更长的刀具寿命;随着切削速度的增加,三种刀具的寿命都有所下降。SEM二次电子图像显示,PCD010和PCD005刀具的磨损机制为硬质点的机械磨损,而晶粒较粗的PCD030刀具的主要磨损机制为机械磨损,同时伴有穿晶磨损。     

制备PCD刀具的关键工序

随着中国汽车工业的高速发展,PCD刀具被广泛应用于以发动机和变速箱为代表的汽车零部件加工。对于PCD刀具,特别是各种高精度、非标准复合PCD刀具,PCD复合片的焊接、PCD刀具的线切割和刃磨等关键工序在很大程度上决定了PCD刀具的加工精度和刀具寿命。本文主要研究了PCD刀具的焊接、线切割和刃磨等关键工序。     

PCD和硬质合金刀具车削钛基复合材料时刀具磨损特征研究

以原位生成晶须和颗粒混合增强钛基复合材料为车削对象,在切削速度为60~120m/min的条件下,对聚晶金刚石（PCD）和硬质合金刀具开展了车削性能试验研究。研究表明,PCD刀具的切削力为硬质合金刀具的77%～88%,其切削温度为硬质合金刀具的65%～82%。无论是高速切削,还是低速切削,PCD刀具都经历初期剧烈磨损而后稳定磨损的过程,而硬质合金刀具仅有急剧磨损的过程。刀具磨损特征方面,PCD刀具主要发生磨粒磨损和黏结磨损,硬质合金刀具主要发生月牙洼磨损、黏结磨损和扩散磨损。     

Performance of single crystal diamond tools with different rake angles during micro-grooving on electroless nickel plated die materials

In this study, experiments were carried out to establish the effect of tool rake angle on the performance of single crystal diamond tools in micro-grooving of electroless nickel plated molding dies. Diamond tools with rake angles of 0⁰,+5⁰ and ?5⁰ were used in the study, and it was found that the diamond tool with 0⁰ rake angle has superior performance in terms of tool wear, cutting forces, and machined surface roughness. For a cutting distance of up to 11.69 km, the 0⁰ rake tool machined satisfactorily without any sign of tool wear while the tools with +5⁰ and ?5⁰ rake angles suffered from progressive wear with a corresponding increase in cutting forces. However, it was noted that despite the increase in wear on tools with +5⁰ and ?5⁰ rake angles, and cutting forces on the diamond tools with all three different rake angles did not significantly affect the surface roughness. The effects of various cutting parameters such as spindle speed and infeed rate on the cutting forces and surface roughness are also presented in the study. It was observed that cutting forces increase proportionately with spindle speed and infeed rate without any significant variation of surface roughness. Surface quality of up to 3 nm Ra was achieved during micro-grooving of electroless nickel.     

PCD刀具超精切削表面质量的研究

用人造聚晶金刚石 (PCD)和天然单晶金刚石 (SPD)刀具对无氧铜材料进行了切削试验 ,对加工表面质量进行了检测和分析。结果表明 :两种刀具在超精切削中获得的加工表面质量具有相似性 ,因此PCD刀具在一定程度上可替代SPD刀具进行超精切削加工。     

粗粒度人造多晶金刚石用作超精切削加工刀具材料的可能性

用粗粒度的人造多晶金刚石刀具进行车削试验．从理论和实验两方面对此种刀具切削形成超精密加工表面的机理进行了研究，提出了＂微量切削过程中．人造多晶金刚石刀具多点切削、单点成形＂的观点。在与天然单晶金刚石刀具的切削试验结果以及天然单晶金刚石刀具超精切削加工生产条件进行对比之后，验证了粗粒度人造多晶金刚石用作超精切削加工刀具材料的可能性。