单晶硅和单晶铝纳米切削过程比较

采用分子动力学模拟方法进行了单晶硅和单晶铝纳米切削过程的比较研究．硅原子间相互作用力采用Tersoff势计算，铝原子间和工件与刀具原子间相互作用力采用Morse势计算．通过对切削过程中切屑和加工表面、能量和切削力的分析，发现硅发生非晶态相位变换和切屑体积改变，但没有位错和弹性恢复产生；而铝发生的现象却与硅相反．     

单晶硅和单晶铝纳米切削过程比较

采用分子动力学模拟方法进行了单晶硅和单晶铝纳米切削过程的比较研究，硅原子间相互作用力采用Tersoff势计算，铝原子间和工件与刀具原子间相互作用力采用Morse势计算．通过对切削过程中切屑和加工表面、能量和切削力的分析，发现硅发生非晶态相应变换和切屑体积改变，但没有位错和弹性恢复产生；而铝发生的现象却与硅相反。     

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.     

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.     

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.     

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力先上升后下降的现象, 这与二者高温下产生的润滑氧化物有关。切削温度和工件粗糙度都与后刀面磨损量有正相关关系, 即随着后刀面磨损量的增加, 温度和粗糙度都随之增加, 但温度的增加还与前刀面第一变形区塑性变形增大, 热量增加有关。另外, 2种刀具产生的切屑尺寸、颜色、锯齿频率也证明了AlCrSiN涂层刀具磨损较慢,切削温度较低。     

微切削加工Al7050-T7451过程切屑形貌及尺度效应研究

采用硬质合金刀具,通过一系列的单因素直角切削试验对铝合金7050-T7451微切削加工中的切屑形貌、切削力以及尺度效应等进行了研究。为了便于使用Kistler9257B型测力仪进行加工过程切削力的测量,对工件进行处理,使用数控铣削中心实现直角车削。试验方案在不同切削速度下变换切削深度,考虑刀具刃口半径的存在对微切削加工过程的影响。试验中收集不同切削参数下的切屑,得到切屑的宏观形貌;对切屑进行抛光腐蚀,在高倍光学显微镜下获取切屑的微观形貌,研究了切削参数对切屑厚度和卷曲程度等的影响规律。试验过程中实时测得不同切削条件下的切削力,讨论了微切削加工过程切向力和径向抗力受刀具刃口半径影响下的变化规律,并从单位切削力的角度出发研究了刀具刃口半径对微切削加工过程中尺度效应的影响规律。     

基于Deform的精车过程中的切屑热仿真

精车过程中会产生大量的切削热,如果切削热不及时传散,切削区的平均温度将会大幅度地上升,使工件、刀具和机床产生热变形,影响加工精度、表面质量和刀具寿命,造成工件表面的热损伤,还会产生有害的残余应力.运用Deform软件对精车过程进行仿真,分析了精车过程中的温度和应力变化和分布.结果表明:刀具的最高温度为1 690℃,切屑的最高温度为1 090℃,工件的最高温度为747℃,工件的等效应力最大值为1 160 MPa.     

硬质合金刀具切削过程中扩散磨损的数值模拟

针对硬质合金刀具切削奥氏体不锈钢粘刀现象严重的问题,利用热力学软件ThermoCalc中的TCC模块和DICTRA模块,模拟了硬质合金刀具与被切削工件之间发生的原子扩散,主要对Fe—Co,Cr—Co、Ni—Co,Mn—Co元素之间的相互扩散以及C在刀具表面的富集情况进行模拟．证实刀具与工件之间发生的原子间相互扩散是发生粘刀现象的主要原因。     

基于 Deform 的精车过程中的切屑热仿真简

精车过程中会产生大量的切削热,如果切削热不及时传散,切削区的平均温度将会大幅度地上升,使工件、刀具和机床产生热变形,影响加工精度、表面质量和刀具寿命,造成工件表面的热损伤,还会产生有害的残余应力.运用Deform软件对精车过程进行仿真,分析了精车过程中的温度和应力变化和分布.结果表明：刀具的最高温度为1 690℃,切屑的最高温度为1 090℃,工件的最高温度为747℃,工件的等效应力最大值为1 160 MPa.     

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.     

Molecular dynamics simulation of single crystal Nickel nanometric machining

Molecular dynamics simulation is carried out to study the nanometric machining of single crystal Nickel (Ni). Through an investigation of atomic displacement and the variation of cutting force, it is found that the latter is in accordance with the number variation of elastic displaced atoms in the workpiece. It is further found that the generation of complex stacking faults is the predominant cause of cutting force fluctuation, and the stacking faults with complex structures lead to work-hardening. The temperature of the cutting tool and workpiece is studied during the machining process. It is concluded that the selection of averaging steps has a significant influence on the system temperature distribution. Thus, the time-spatial averaging method, which has a high accuracy and consistency in temperature distribution, is proposed.     

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.     

模具钢Cr12MoV精密硬态切削过程刀具磨损

模具钢Cr12Mo V硬态切削过程中,工件材料的高硬度导致了刀具在切削过程中受到剧烈的热力耦合作用,刀具的磨损机制也明显不同于常规的切削过程.本研究以PCBN刀具精密硬态切削模具钢Cr12Mo V过程为对象,分析了刀具前刀面和后刀面的磨损规律,通过元素变化分析得到刀具不同位置的磨损机制;通过揭示不同切削速度和进给量下的刀具磨损规律为合理选择切削参数提供理论依据;研究揭示了切削合力和切削三分力受刀具磨损量的影响机制;通过建立磨损刀具的几何模型,采用有限元仿真软件Deform对不同刀具磨损量下的切削过程进行了仿真分析,得到了刀具磨损对切削温度场的影响机制.     

纳米切削单晶铜的准连续介质法模拟

采用准连续介质多尺度方法模拟了单晶铜的纳米切削过程。分别采用原子位置图和应力分布图对纳米切削过程中局部变形进行描述,得出了模型的切削力-切削距离的响应曲线。从微观角度分析了单晶铜纳米切削过程中材料变形、材料去除机理及内部损伤情况。根据模拟结果,对切削过程中位错形核、演化过程、湮灭消失、切屑及加工表面的形成过程进行了深入的分析。从位错演化的角度解释了切削力与应变能曲线的峰谷变化。提出了纳米切削过程中材料受到刀具的挤压作用而导致位错形核。得出了在纳米切削过程中塑性材料的去除是基于位错运动演化的结论。     

Experimental investigation and numerical simulation on interfacial carbon diffusion of diamond tool and ferrous metals

We numerically simulated and experimentally studied the interfacial carbon diffusion between diamond tool and workpiece materials. A diffusion model with respect to carbon atoms of diamond tool penetrating into chips and machined surface was established. The numerical simulation results of the diffusion process reveal that the distribution laws of carbon atoms concentration have a close relationship with the diffusion distance, the diffusion time, and the original carbon concentration of the work material. In addition, diamond face cutting tests of die steels with different carbon content are conducted at different depth of cuts and feed rates to verify the previous simulation results. The micro-morphology of the chips is detected by scanning electron microscopy. Energy dispersive X-ray analysis was proposed to investigate the change in carbon content of the chips surface. The experimental results of this work are of benefit to a better understanding on the diffusion wear mechanism in single crystal diamond cutting of ferrous metals. Moreover, the experimental results show that the diffusion wear of diamond could be reduced markedly by applying ultrasonic vibration to the cutting tool compared with conventional turning.