基于AdvantEdge的6061铝合金高速铣削刀具结构参数优化研究

高速铣削过程中,刀具结构参数对刀具的切削性能有非常重要的影响。本文利用专用切削加工有限元分析软件AdvantEdge对6061铝合金高速铣削刀具进行了有限元分析。采用等效二维有限元仿真方法,结合单因素寻优设计方法,分析了硬质合金和高速钢刀具主要的宏、微观参数(包括刀具刃口钝圆半径、前角和后角等)对铣削加工过程中的温度、应变、切削力等参数的影响趋势。仿真结果显示,为获得较好的切削效果,铣刀取较小的刃口钝圆半径(即0.04mm左右);可取较大的前角和后角,前角为12°-15°,后角为15°-20°。     

基于钛合金三维铣削仿真的立铣刀设计参数优化

以钛合金圆角立铣刀的槽前角、芯厚、齿间角和螺旋角为因子,采用正交实验设计方法,对9种采用不同参数组合的铣刀设计方案侧铣加工Ti-6Al-4V(TC4)进行了三维铣削仿真。根据仿真结果,以切削力和切削温度为刀具性能评价指标,初步优选了3个刀具优化设计方案。通过切削实验,将3个初选方案铣削加工TC4的切削性能与现有方案进行了对比,结果表明3个初选方案中有2个方案的性能要显著好于现有方案,从而证明了有限元切削仿真在刀具设计优化方面有效性,并最终确定了一个最佳方案。     

刀具几何参数对钛合金铣削力和表面完整性的影响

针对TC18钛合金铣削过程,采用正交试验研究了硬质合金刀具几何参数对铣削力和表面完整性的影响,建立了铣削力经验模型,并分析了铣削力对刀具前角、后角和螺旋角的绝对灵敏度和相对灵敏度;采用田口法分析了刀具几何参数对表面粗糙度和表面残余应力的影响。结果表明：大前角、小后角、大螺旋角的条件下铣削力较小,铣削力对刀具螺旋角的变化最敏感,对后角次之,对前角最不敏感;铣削表面均为残余压应力,刀具螺旋角对表面粗糙度的影响显著,刀具后角对表面残余应力的影响显著。     

硬质合金立铣刀铣削难加工材料的仿真研究

基于UG三维建模软件和AdvantEdge有限元仿真软件,对硬质合金立铣刀切削Ti-6Al-4V和Cr12进行切削仿真.通过改变刀具的螺旋角和前角,以切削力和切削温度作为评价标准来优化硬质合金立铣刀,进而改善切削难加工材料的性能.仿真结果表明:硬质合金立铣刀加工Ti-6Al-4V时螺旋角的合理范围为40°～45°,前角范围为8°～10°;硬质合金立铣刀加工Cr12时螺旋角的合理范围为35°～45°,其中以40°附近为最优,前角范围为15°～20°.     

基于切削力仿真分析的倒角钻几何参数优化

在倒角钻的锪孔过程中,硬质合金刀具的前角、后角、基圆百分比和螺旋角对切削力有显著影响。本文采用四因素三水平正交试验法对9组切削试验进行有限元模拟,运用极差分析法获得切削力最小的几何参数组合为前角20°、后角4°、基圆百分比60%、无螺旋角。     

TC4钛合金圆弧形槽切削加工刀具仿真及设计

深海钻铤回路块材料为TC4钛合金,该圆柱形回路块侧面需要铣削4个圆形槽.针对TC4钛合金圆弧形槽的加工,设计一种以W18Cr4V高速钢为基体的切削刀具,并基于热-弹塑性有限元理论建立刀-工有限元切削加工三维模型.对钛合金表面产生的切削力进行仿真计算和预测,通过优化高速钢刀具参数,设计出四刃钛合金铣削刀具,使用此刀具加工...     

钛合金TC4高速切削温度场数值仿真

利用专用有限元切削仿真软件,对钛合金TC4高速铣削温度场进行数值仿真。研究切削参数与刀具几何参数对刀具前、后刀面温度及其分布的影响规律。在设定的切削条件下,仿真结果表明:前刀面和后刀面随主轴转速、每齿进给量和径向切深的增加而有不同程度的温升,而轴向切深几乎不对切削温度产生影响;切削温度随刀具直径的增加而增加,但是随着刀具前、后角的增加,切削温度呈先增后减的趋势。     

高效加工TC4钛合金的铣削过程数值模拟

目前,难加工材料TC4钛合金在切削过程中存在加工效率低、加工表面质量差和刀具使用寿命低等难题。本文针对提高TC4钛合金的加工效率问题,在高速铣削条件下对立铣刀不同轴向切深侧铣加工TC4钛合金进行仿真研究。利用ABAQUS软件建立三维铣削有限元模型并进行相应仿真试验,获取和分析了不同切削条件下的铣削温度场和铣削力波形,并对比了切屑形态。本研究可为高效铣削TC4钛合金实际加工提供理论依据。     

无织构刀具与织构刀具铣削性能对比研究

基于金属切削理论,以无织构刀具和织构刀具为研究对象,对钛合金的铣削过程进行分析与研究,通过改变钛合金的切削条件,研究在不同的切削参数(转速n、背吃刀量ap、侧吃刀量ae、每齿进给量fz)条件下铣削TC4钛合金的铣削力变化趋势并进行分析,为实际加工参数的选择提供参考和依据,具有一定的应用价值。     

TC4钛合金铣削过程的有限元分析

以专业的有限元切削软件The Third Wave AdvantEdge和金属切削理论为基础,将TC4钛合金作为本次研究对象,对钛合金的铣削过程进行分析与研究,通过改变钛合金的切削条件,研究在不同的切削参数(铣削深度ap、铣削宽度ae、每齿进给量fz、转速n)条件下TC4钛合金的铣削力和切屑的变化趋势并进行分析,为实际加工参数的选择提供参考和依据,具有一定的应用价值。     

Study on cutting temperature during milling of titanium alloy based on FEM and experiment

A finite element model of helix double-edge cutting was developed to study cutting temperature during milling of titanium alloy Ti6Al4V. To improve the accuracy of finite element simulation, a new method to construct material constitutive model was presented, and material constitutive model with big strain, high strain rate, and high-temperature characters for aeronautical titanium alloy in cutting process was established. Using this finite element model, milling process of titanium alloy was simulated. Cutting temperature change curves and values were obtained. An analysis indicates that the highest cutting temperature lies in tool-chip interface and is more close to cutting edge; moreover, the temperature is higher in rake face than flank face of the tool. The embedded semi-artificial thermocouple cutting temperature experiment was improved by substituting constantan band for constantan wire. By comparing the results obtained from finite element simulation and cutting temperature experiment results, a good agreement is found, showing finite element simulation analysis of cutting temperature for titanium alloy is correct.     

A novel mathematical model for grinding ball-end milling cutter with equal rake and clearance angle

In this paper, new mathematical models and grinding methods of ball-end milling cutter were proposed based on the orthogonal spiral cutting edge curve. In order to avoid interference, a conical wheel was also designed and employed to grind the rake and rear faces of ball-end milling cutter on a five-axis grinder. Mathematical models of both rake face with equal rake angle and rear face with equal clearance angle were established to improve the machining characteristics of ball-end milling cutter. The design and simulation software of ball-end milling cutter was developed to design and optimize different shapes of both rake face and rear face. Furthermore, grinding experiment of the new ball-end milling cutter was carried out to confirm the validation of the mathematical models.     

Simulation-based solid carbide end mill design and geometry optimization

Designing a high-performance solid carbide end mill is difficult due to the complex relationship between end mill geometry and numerous or conflicting design goals. Earlier approaches of computer-aided solid end mill design are limited to only a few design aspects. This article presents a three-dimensional finite element method of milling process for solid carbide end mill design and optimization. The software was secondarily developed based on UG platform, integrating the parametric design with the development of the two-dimension drawing of solid carbide end mill. The three-dimension finite element simulation for milling Ti-6Al-4V alloy was performed and the geometrical parameters were optimized based on the objective of low cutting force and cutting temperature. As a result, a simulation-based design and optimization of geometrical parameters of tool structure and cutting edge is possible. The optimized results, for the geometrical parameters of tool structure and cutting edge when milling titanium alloy using a 20-mm diameter solid carbide end mill, is a 12-mm diameter of inner circle, four flutes, a 45 ° helix angle, and a 9 ° rake angle of the side cutting edge.     

合金铸铁高速切削的有限元模型

提出了进行高速切削有限元模拟的过程,研究了刀屑间的摩擦和热传递等关键技术,通过高速压缩试验,获得了钼铬铸铁力学性能,建立了钼铬铸铁高速切削的有限元模型。在通过切削力试验对钼铬铸铁高速切削加工过程中的切削温度、应力分布和切屑的形成等进行了验证。分析结果表明该有限元模型可以用来进行钼铬铸铁的高速切削过程仿真,为进一步的研究提供了基础。     

On modeling of cutting forces in micro-end milling operation

Micro-end milling is used for manufacturing of complex miniaturized components precisely in wide range of materials. It is important to predict cutting forces accurately as it plays vital role in controlling tool and workpiece deflections as well as tool wear and breakage. The present study attempts to incorporate process characteristics such as edge radius of cutting tool, effective rake and clearance angles, minimum chip thickness, and elastic recovery of work material collectively while predicting cutting forces using mechanistic model. To incorporate these process characteristics effectively, it is proposed to divide cutting zone into two regions: shearing- and ploughing-dominant regions. The methodology estimates cutting forces in each partitioned zone separately and then combines the same to obtain total cutting force at a given cutter rotation angle. The results of proposed model are validated by performing machining experiments over a wide range of cutting conditions. The paper also highlights the importance of incorporating elastic recovery of work material and effective rake and clearance angle while predicting cutting forces. It has been observed that the proposed methodology predicts the magnitude and profile of cutting forces accurately for micro-end milling operation.     

Effects of Cutting Angles in Ti-6al-4v Milling Process on Surface Integrity: Influence of Roughness and Residual Stresses on Fatigue Limit

□ The influence of the milling process on the fatigue behavior of a titanium alloy was investigated. The effect of cutting conditions such as the cutting angles (axial and radial rake angle) on the surface integrity (roughness and the residual stresses) was observed. The results indicated that the cutting angles have a limited influence on roughness parameters, whereas the effects on residual stresses were greater. A negative axial rake angle induced compressive residual stresses regardless of the radial rake angle. In contrast, a positive axial rake angle combined with negative radial rake angle induced tensile residual stresses. To evaluate the fatigue limit, the four point fatigue tests were carried out. Result showed the fatigue limit is sensitive to the surface integrity. The fatigue limit was also evaluated by analytical method (Arola model). A good correlation was found between the analytical results and the experimental results when cutting angles induced compressive residual stress. However the Arola model was less accurate for tensile residual stress surface condition. To improve the prediction precision, the residual stress was considered as a sensitivity parameter and added to Arola model.     

TC4钛合金深槽插铣加工

针对钛合金深槽开槽加工效率较低的问题,对TC4钛合金深槽进行插铣开槽试验研究,并对其已加工表面形貌、切屑形态、刀具磨损及切削效率进行了分析。结果表明:插铣加工表面粗糙度较大,铣刀的端面刃为主切削刃,刀具磨损主要发生在铣刀的端面刃。对于钛合金深槽的开槽加工,插铣加工切削过程平稳,具有比层铣更高的切削效率。     

AlTiN涂层刀具精铣TC4钛合金工艺参数的影响与优化

采用AlTiN涂层4刃?10 mm硬质合金立铣刀,在VMC850立式加工中心上对TC4钛合金进行铣削精加工试验。利用高精密数字化检测设备,对加工成形的TC4钛合金试件表面粗糙度、平面度、平行度、表面形貌、残余应力及显微硬度测量。分析AlTiN涂层刀具在设定不同工艺参数条件下TC4钛合金的整体加工质量和表面形貌变化规律。结果表明:在主轴转速n=8000 r/min、每齿进给量f z=0.04 mm/z、切削深度Δd=0.5 mm的最优精铣工艺参数下,TC4钛合金工件的加工质量和表面形貌好,刀具寿命长,其平面度为0.39μm,平行度为0.33μm,表面粗糙度为0.70μm,表面残余应力为-175 MPa,表面显微硬度为269 HV 0.2,实现了TC4钛合金的高质量高效率的精铣加工。     

不同槽型铣刀片铣削过程振动分析

机械加工中工艺系统的振动破坏了零件的加工精度。刀具与工件之间的冲击力是引起振动的主要原因之一。通过对带有三维复杂槽型的波形刃铣刀片与平前刀面铣刀片铣削力和铣削振动的对比试验、铣削力的有限元数值模拟,表明带有三维复杂槽型的波形刃铣刀片铣削力小,铣削过程中引起工艺系统的振动较平稳。可以断言,优化刀具的结构与几何参数可有效地减小铣削过程的振动现象。