精密加工中切削参数对毛刺尺寸的影响

毛刺的产生是金属切割加工中长期存在的问题,在实际的基础上通过对精密车削中进给方向毛刺的研究,分析了切削参数对毛刺尺寸的影响,为毛刺生成的研究以及毛刺的抑制和去除做了部分基础性工作。     

微切削毛刺形成机理及研究进展综述

概述了微切削毛刺的形态、分类及其生成机理;阐述了微切削毛刺的仿真分析研究进展;在微切削毛刺的试验研究进展方面,分析了切削工艺参数、刀具几何、切削方式和辅助工艺对微切削毛刺的影响;介绍了几种常用复合材料加工毛刺的研究现状;根据毛刺的成形机理和加工方式,综述了去除毛刺的工艺方法与设备,提出了去毛刺装置的性能要求;最后总结了微细毛刺研究方面的不足,并指出了将来研究的方向。     

二维切削中切削方向毛刺与亏缺的界限转换条件

建立了二维切削中切削方向毛刺与亏的生成模型,给出了切削方向毛刺与亏缺的判别准则,并对影响切削方向毛刺与亏缺转换的主要因素进行了实验研究和相应的理论分析,提示出切削方向毛刺与亏缺的界限转换条件为：剪切应变ε≤3,为亏缺;3＜ε＜4,为过渡区;ε＞4,为毛刺。并且,切削方向毛刺与亏缺的界限转换条件因切削条件变化而变化。为进一步深入研究切削毛刺的生成与抑制理论提供了科学的基础。     

微细切削毛刺发展研究

微细切削加工中形成的毛刺严重降低了被加工微型零部件的精度和棱边质量,影响了工件的使用性能,对微细切削的毛刺研究有利于推动微细切削技术的发展。系统概述了国内外微细切削毛刺的研究进展,重点阐述了研究者对微细切削毛刺形成机理、影响因素及预测预报技术的研究,并在分析微细切削特殊切削环境的基础上,结合尺度效应理论研究了微细切削毛刺的形成机理,指出了微细切削毛刺研究尚存的主要问题,同时确立了今后深入开展微细切削毛刺研究的发展方向。     

金属切削毛刺数据库系统的设计

毛刺的产生和存在是金属切削加工中普遍存在的问题 ,它直接影响了工件的加工精度及质量。基于数据库和Java ,研究了金属切削毛刺数据库系统的设计 ,实现了切削毛刺数据的管理、切削毛刺类型与尺寸大小及加工参数的查询 ,进一步丰富和完善了金属切削毛刺的预报与控制理论。     

切削方向毛刺/亏缺的形成及其界限转换

基于切削方向毛刺/亏缺的形成过程,利用最小能量原理,建立切削方向毛刺/亏缺的数学模型,初步确定了切削方向毛刺/亏缺形态界限转换的基本准则。     

金属切削毛刺专家系统的研究进展

毛刺是金属切削加工中产生的常见现象之一,它的尺寸和形状直接影响到工件的尺寸精度和形位精度,甚至影响到工件的使用性能及其寿命.随着机械制造业朝着高精度,高效率和自动化方向发展,对切削加工精度的要求越来越高.由于专家系统具有数据结构化,数据和应用程序的高度独立性、数据共享,并将数据冗余减少到最小限度等优点,在金属切削毛刺形成研究与控制上逐步得到了越来越广泛的应用,对加工精度起到了很好的效果.在分析现有毛刺研究成果的基础上,与专家系统进行了对比与分析,体现出了专家系统在毛刺研究领域应用具有的优点,并阐述了现有的金属切削毛刺专家系统的研究现状,指出了尚存在的一些问题,从而为今后毛刺专家系统的发展提供借鉴.     

镍磷合金微沟槽金刚石切削泊松毛刺形成机理

为了探究镍磷合金超精密切削过程中泊松毛刺的形成原因及规律,并且寻求泊松毛刺尺寸更精准的表征方式,本文通过对镍磷合金泊松毛刺的形成机理进行理论分析,建立其正交切削过程中的泊松毛刺高度和宽度预测模型,并通过实验分析切削参数对泊松毛刺高度和宽度的影响,通过实验观察可知,切削深度对毛刺尺寸影响显著,切削深度由3μm增加至9μm时,毛刺高度增加了0.099 8μm,毛刺宽度增加了1.06μm,而切削速度对毛刺高度及宽度的影响很小。且通过对比实验得到的毛刺数据和预测数据可知,毛刺高度和宽度预测模型的平均相对误差值分别为5.43%和8.17%,验证了预测模型的准确性。同时目前的泊松毛刺高度和宽度表征方法具有一定的误差,因此本文提出了利用积分法计算泊松毛刺体积的方法,并基于体积法建立了更准确的泊松毛刺尺寸表征方法,通过计算得到体积的预测模型平均相对误差值为4.81%,可知泊松毛刺体积的预测模型准确度相对更高。研究结果为镍磷合金正交切削过程中合理选择切削参数和泊松毛刺尺寸评估方法提供了理论指导。     

去毛刺是不可忽视的工序

去毛刺是不可忽视的工序一汽集团公司工艺研究所（长春１３００１１）徐立收稿日期：１９９７年８月一、毛刺生成原因及去毛刺的必要性１．毛刺生成原因切削加工后的工件上带有毛刺有多种原因,主要与工件材料、切削用量、刀具类型、刀具几何参数、切削力和工件形状等有关...     

金属切削毛刺生成机理的研究及其发展

对国内外金属切削毛刺生成机理的研究沿革及现状进行系统的概述与分析，指出金属切削毛刺研究中尚待解决的主要问题及其发展前景。     

金属切削毛刺专家知识系统的开发

毛刺是金属切削加工中产生的常见现象。研究开发出了金属切削毛刺专家知识系统，为管理切削实验所测的毛刺数据、查询毛刺类型与尺寸、优化选择加工参数和进行切削毛刺形成的动力学仿真等奠定了基础。进而，为实现切削毛刺的预报与控制开辟了新途径。     

基于毛刺的切削参数优化试验研究

金属切削中的毛刺是切削加工中产生的常见现象,它严重地影响产品的精度和使用性,有必要对毛刺的预测进行深入的研究。本文针对铣槽时产生的出口毛刺高度进行试验与检测,并通过田口直交表进行统计分析,对检测到的试验数据运用相关公式进一步进行计算优化,然后根据传统的经验值与优化计算的数据进行比较,获取了以毛刺高度为控制对象的切削用量优化值,以此为依据提出在加工过程中夹具、机床等相关的数据优化,为进一步对毛刺控制的非线性数学模型的建立提供试验数据。     

Effect of polar organic substance on burr formation in orthogonal cutting

The initiation of burr formation is characterized by the initial negative shear angle and the initial tool distance which are obtained from the minimum energy principle and energy conservation at the chip/burr transition point. Specially in this report the rollover burr is dealt as a specific case of the chip formation process in the final stage of cut, which the tool moves toward the end of workpiece. The purpose of this paper is to experimentally invesigate the burr formation mechanism near the end of cut by using a copper with various cutting conditions and tool geometries, and the influence of the surface active medium, that was used to reduce the burr size and improve the machinability, upon the mechanism of burr formation in the orthogonal cutting using the milling machine.     

Investigation on the burr formation mechanism in micro cutting

It is desirable to minimize burr formation for improving part quality. This paper presents an investigation on the burr formation mechanism in micro cutting by taking into consideration the stress distribution around the cutting edge arc. The influences of the uncut chip thickness and the cutting edge radius on burr formation were investigated. Poisson burr is attributed to the side flow of the stagnation material at the bottom of the cutting edge arc. The stress distribution at the cutting edge arc has great influence on Poisson burr formation. The burr height decreases to the minimum value and then increases with reducing the uncut chip thickness due to the change of the maximum stress distribution. An optimum machining strategy also is suggested in micro milling of snake-shaped groove microstructure.     

Characterization and modeling of burr formation in micro-end milling

Mechanical micromachining is increasingly finding applications in fabrication of components in various fields, such as, biomedical devices, optics, electronics, medicine, communications and avionics. In order to ensure adequate functionality, there are stringent requirements for form and finish in case of biomedical devices like cochlear implants and metallic optics. This necessitates that the post machined surface must be burr free. To address these issues in micromachining, this paper presents results of an experimental study to investigate the influence of main process parameters i.e. speed, feed rate, depth of cut, tool diameter and number of flutes on the formation of the various types of burrs i.e. exit burrs and top burrs produced during micro-end milling operation. The experiments performed using Taguchi method shows that three types of burr formation mechanisms prevail during micro-end milling operations; these are: lateral deformation of material, bending and tearing of the chip. Also, three types of burrs were observed include: Poisson burr, rollover burr in down milling and tear burr in up milling. Further, it is observed that the depth of cut and the tool diameter are the main parameters, which influence the burr height and thickness significantly. However, the speed and the feed rate have small to negligible effect on the burr thickness and height. Besides the experimental analysis, the paper presents an analytical model to predict the burr height for exit burr. The model is built on the geometry of burr formation and the principle of continuity of work at the transition from chip formation to burr formation. Note that prediction of burr height in micro-end milling is extremely challenging due to the complex geometry of material removal and microstructural effects encountered during cutting at that length scales. The model fares well and the prediction errors range between 0.65 and 25%.     

Experimental investigations of sideward burr formation in rotary machining

Burrs can be formed on the feed mark ridges and the edges of the machined parts in machining operations. These burrs are undesirable in terms of the surface quality, the precise dimensioning of the machined parts and the safety of operators. This paper demonstrates the effectiveness of using a rotary tool on minimizing the sideward burr formation in machining. In particular, the experimental relationships between the size of sideward burr and the cutting parameters (including tooling mechanism) are established first in rotary machining. Methods to control the size of sideward burr are then explained. The possible application of a rotary tool for deburring operations while engaged in machining is also explored.     

微细铣削毛刺形成研究

微细铣削是在广泛材料范围内制造精密三维微小零件的一种柔性的、经济的加工方法,微细铣削的主要问题之一是有毛刺产生,对微细铣削过程中毛刺的形成及其影响因素进行实验研究与分析,得到微细铣削过程中各因素对毛刺形成影响的一般规律,在此基础上,通过合理地选择切削参数以及刀具路径规划,达到减小毛刺的目的。     

Methodology of Taguchi optimization for multi-objective drilling problem to minimize burr size

Formation of exit burr on part edges during drilling has several undesirable features with regard to product quality and functionality. Hence it is essential to select optimum drilling process parameters to minimize burr size at the production stage. This paper presents the application of the Taguchi optimization method for simultaneous minimization of burr height and burr thickness influenced by cutting conditions and drill geometry. The Taguchi design approach to the multi-objective optimization problem is based on the introduction of a new concept of fitness function for each trial of orthogonal array. The fitness function is derived through mapping the objective functions of the drill optimization problem. In the present work, optimal values of cutting speed, feed, point angle and lip clearance angle are determined for selected drill diameter values to minimize burr height and burr thickness during drilling of AISI 316L stainless steel workpieces. The details of experimentation, analysis of means and analysis of variance are presented in the paper.     

工艺设计中的毛刺预防和控制

针对零件毛刺对产品质量的影响。介绍了一些在进行零件工艺设计时预防和减少零件毛刺的方法及措施。实践表明这些方法实用、有效。