SiCp/Al复合材料薄壁件车削加工变形的仿真研究

通过建立Si Cp/Al复合材料薄壁件的三维有限元模型,运用ABAQUS有限元软件对其车削加工过程进行模拟分析,研究了切削速度、进给量和背吃刀量等切削参数对薄壁件加工变形的影响规律。结果表明,在工件端部对Si Cp/Al复合材料薄壁件进行切削时,最大径向变形和最大挠曲变形都发生在切削区域,并随着背吃刀量的增加而增大,随着进给量的增大而增大,随着切削速度的提高呈增大趋势。其中背吃刀量对Si Cp/Al复合材料薄壁件变形的影响最显著,切削速度影响较小。     

SiCp/Al复合材料薄壁件高速正交车铣切削力的仿真研究

把正交车铣方法应用到复合材料薄壁件的加工中,使用ABAQUS有限元仿真软件,建立了Si Cp/Al复合材料车铣薄壁件的仿真模型,通过高速正交车铣仿真实验研究了切削速度、工件转速、进给量和切削深度对切削力的影响规律。仿真实验得出切削深度对切削力影响最大,随切削深度的增加车铣切削力明显增大,因此该因素的参数选择在切削加工中应着重考虑;而其它三个因素对切削力的影响次之且影响程度相当,切削力变化趋势一致,都是随各因素参数增加而略有增大。     

基于正交试验的高速切削钛合金切削力研究

随着钛合金在各行业的广泛应用,钛合金的高速切削加工技术成为航天航空工业及其他制造业中的难题之一。切削力是研究切削过程的重要物理量之一,其大小和变化对工件加工品质、刀具磨损和寿命等都具有影响。本文以钛合金Ti6Al4V为研究对象,用正交试验的方法分析了切削速度、进给量和背吃刀量三个因素对切削力的影响,结果表明:径向力、切向力、轴向力都是随切削速度增大而减小,随进给量和背吃刀量的增大而增大,切削用量的变化导致各向切削力与切削合力的变化趋势基本一致;背吃刀量对切削力影响最大,进给量次之,切削速度最小;三个方向力中,轴向力最小,径向力次之,切向力最大。     

工件尺寸对高速车铣SiCp/Al复合材料薄壁件切削力的影响研究

使用ABAQUS有限元软件对Si Cp/Al复合材料薄壁件的高速车铣加工进行仿真研究,分析工件几何尺寸即工件直径、壁厚和工件的夹持悬伸量对车铣切削力的影响规律。仿真得出:工件直径对切削力的影响最为明显,随工件直径增加的开始阶段车铣切削力的变化幅度较小,但之后再随尺寸增加切削力明显上升;工件壁厚和工件夹持悬伸量对车铣切削力的影响次之,工件壁厚增加,切削力开始上升,之后变化幅度减小;而随悬伸量的增加切削力有先增后减的趋势。从对三向力的影响来看,工件尺寸和悬伸量变化对Fx'方向力影响最大,对Fy'和Fz'影响很小或几乎没影响。薄壁回转体的尺寸参数和悬伸量直接影响工件的刚度,在切削加工中对切削力的影响比较大,因此该仿真研究对薄壁件车铣加工实践具有重要的指导意义。     

碳化硅晶须增强铝基复合材料的切削力实验研究

采用三种不同种类的刀具对碳化硅晶须增强铝基复合材料(SiCw/2024)进行车削试验,用Kistler三向测力系统检测切削力波形和三向切削分力Fc、Fp、Ff。试验结果表明,对增强相体积分数超过某一阈值(如17～18%)的碳化硅晶须增强铝基复合材料,用K类硬质合金(K10TiAlN)固定式刀具切削,会出现背吃刀抗力Fp、进给分力Ff大于主切削力Fc的现象,三者大小的关系为Fp>Ff>Fc,且随着SiCw含量的增高切削力差值越大;用硬质合金圆形自回转刀具切削,平均背吃刀抗力Fp减少(30～60)%;用PCD刀具切削,三向切削力都最小。     

基于正交实验的45钢车削性能的研究

用硬质合金车刀,采用正交实验法进行45钢车削力的实验,得到转速、进给量、背吃刀量与切削力的关系,主切削力随进给量的增大而增大,背吃刀量的增大而增大,当速度大于50m/min,主切削力随速度的增大而减小.其中背吃刀量的影响最大,其次是进给量,速度的影响效果最低.正交实验所得的经验公式Fz=2685ap0.98 f 0.744 v - 0.153 , Fy=1912 ap0.88 f 0.59 v - 0.153 ,Fx=2834ap1.02f 0.51 v - 0.4.     

切削用量对TC4薄壁件铣削力的影响

TC4薄壁零件刚性较低,切削力容易使工件变形。为了提高加工质量,研究了切削用量对铣削力的的影响规律,并建立了和铣削力相关的经验公式。结果表明:切削力Fx和Fy与切削速度呈负相关,而切削力Fz与切削速度呈正相关;切削力Fx、Fy随每齿进给量、轴向以及径向切削深度的增大而增大,其中对切削力影响最大的因素为径向切深。     

金刚石圆锯片锯解花岗石切削力及参数优化的实验研究

基于金刚石圆锯片锯解花岗石的切削力正交实验研究,对切削速度、进给速度和背吃刀量三因素影响切削力的显著性进行极差分析,得出切削力Fx、Fy、Fz随切削速度的增大而减小,随进给速度和背吃刀量的增大而增大的变化趋势。通过回归分析建立切削力数学模型并进行量化分析,得出切削速度对切削力Fx的影响要比对切削力Fy和Fz大、背吃刀量对切削力Fz的影响要比对切削力Fx和Fy大的结论,并以材料去除率和切削力为评价指标对工艺参数进行优化,得到用于生产加工的最佳工艺参数组合。     

车削参数对超高强度钢车削性能的影响

通过正交仿真试验分析300M钢在车削过程中切削速度V、背吃刀量a_p、进给量f以及刀尖圆弧半径r_ε对车削300M钢切削力的影响。采用方差分析法和极差分析法确定车削参数的最优组合,并检验4个因素对切削三向力的显著性。结果表明,4个因素中,背吃刀量a_p对切削力的影响最为显著,其次是进给量和刀尖圆弧半径,切削速度对切削力的影响程度最小。使用MATLAB软件对切削三向力与各个因素之间的关系进行多元线性回归分析,并建立切削三向力经验公式。通过对比分析经验公式与仿真分析得到的三向力,确定经验公式准确可靠。     

切削用量对PCBN刀具车削钛合金的切削性能影响

为了研究不同的切削用量对PCBN刀具干式车削钛合金的影响。利用有限元仿真软件,模拟PCBN刀具干式车削钛合金实验,结果表明:随着背吃刀量和进给量的增加切削力在增大,其中背吃刀量对切削力的影响程度最大;切削速度对切削温度的影响程度最大。     

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。     

高速车削镍基高温合金GH4169的切削力仿真研究

基于Deform 3D仿真软件建立了GH4169高温合金高速车削的有限元模型,采用四因素三水平正交试验方法研究了切削用量和刀具几何参数对切削力的影响规律,并建立了切削力经验公式。研究结果表明:在高速车削GH4169的过程中,对切削力影响最大的参数是切削深度,其次是进给量和前角,最后是刀尖圆弧半径;切削力随切削深度和进给量的增大而增大,随前角的增大呈现先降低又升高的趋势,而刀尖圆弧半径增大时切削力变化不大;最佳参数组合为:进给量0.2mm/r,切削深度0.4mm,前角10°,刀尖圆弧半径0.2mm。     

Development of a three-component dynamometer to measure turning force

This work is focused on the design, construction and testing of a strain gauge dynamometer devised to measure the three components of the turning force. For this purpose, an elastic element sensitive to torsion and flexion was developed. The effect of the cutting parameters (cutting speed, feed rate and depth of cut) on the force components was investigated. Additionally, the performance of the dynamometer was compared with a commercial piezoelectric device. The results indicated that the three components of the turning force decrease slightly as cutting speed was elevated and increase linearly with feed rate and depth of cut. Furthermore, the analysis of variance indicated that the three components are not significantly affected by cutting speed; however, they are significantly affected by feed rate and depth of cut. The comparative tests indicated that the strain gauge dynamometer presented a satisfactory performance, providing closer values to the piezoelectric dynamometer at higher depth of cut values.     

Influence of machining parameters on the machinability of particulate reinforced Al/SiC–MMC

The paper presents the result of an experimental investigation on the machinability of silicon carbide particulate aluminium metal matrix composite during turning using a rhombic uncoated carbide tool. The influence of machining parameters, e.g. cutting speed, feed and depth of cut on the cutting force has been investigated. The influence of the length of machining and cutting time on the tool wear and the influence of various machining parameters, e.g. cutting speed, feed, depth of cut on the surface finish criteria has been analyzed through the various graphical representations. The combined effect of cutting speed and feed on the flank wear has also been investigated. The influence of cutting speed, feed and depth of cut on the tool wears and built-up edge is analyzed graphically. The job surface condition and wear of the cutting tool edge for the different sets of experiments have been examined and compared for searching out the suitable cutting condition for effective machining performance during turning of Al/SiC-MMC. Test results show that no built-up edge is formed during machining of Al/SiC-MMC at high speed and low depth of cut. From the test results and different SEM micrographs, suitable range of cutting speed, feed and depth of cut can be selected for proper machining of Al/SiC-MMC.     

LD10铝合金车削力模型的建立

对LD10铝合金棒料进行车削力测试,并建立了车削过程的有限元模型,通过回归分析获得了试验铝合金的车削力模型,分析了车削深度、进给量和车削速度对车削力的影响。结果表明:试验及有限元模拟结果的精度均满足工程应用的要求,两者吻合较好;车削力模型的预测值具有较高的准确性,可以用于相应的理论及工程应用。     

Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization

In this study, the effects of cutting speed, feed rate, workpiece hardness and depth of cut on surface roughness and cutting force components in the hard turning were experimentally investigated. AISI H11 steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7020 from Sandvik Company) which is essentially made of 57% CBN and 35% TiCN. Four-factor (cutting speed, feed rate, hardness and depth of cut) and three-level fractional experiment designs completed with a statistical analysis of variance (ANOVA) were performed. Mathematical models for surface roughness and cutting force components were developed using the response surface methodology (RSM). Results show that the cutting force components are influenced principally by the depth of cut and workpiece hardness; on the other hand, both feed rate and workpiece hardness have statistical significance on surface roughness. Finally, the ranges for best cutting conditions are proposed for serial industrial production.     

基于AdvantEdge的斜角车削仿真实验确定刀屑摩擦因数的方法

当使用AdvantEdge软件进行切削仿真实验时,刀屑摩擦因数对仿真结果的影响明显,但现有有限元软件未提供刀屑摩擦因数数据库。为建立一种基于AdvantEdge的斜角车削仿真实验的刀屑摩擦因数确定方法,首先提出基于斜角车削的摩擦力计算方法,然后建立AdvantEdge三维斜角车削仿真模型,设定不同切削速度、切削深度、进给量及摩擦因数,通过AdvantEdge仿真正交试验,获得刀屑摩擦因数的经验计算公式。为验证刀屑摩擦因数经验计算公式的正确性,设定不同切削速度和切削深度及进给量的斜角车削正交试验,获得切削力数据,并基于摩擦因数经验计算公式求得对应刀屑摩擦因数。利用求得的摩擦因数数据修改AdvantEdge中刀屑摩擦因数参数,进行残余应力切削仿真实验。仿真实验获得的残余应力与实际切削实验获得的残余应力相比,误差在10%以内,证明提出的刀屑摩擦因数确定方法是正确的。     

Thermomechanical modeling of oblique turning in relation to tool-nose radius

This article aims at predicting machining performances for oblique turning in relation to tool-nose radius. A new geometric analysis for the uncut chip area is proposed as function of depth of cut, feed rate, tool-nose radius, and edge direction angle. Cutting edge is discretized into increments and average uncut chip thickness, elementary direction angle and elementary depth of cut are determined for each one. A new thermomechanical model is developed for each increment which is supposed to be an oblique machining with single cutting edge. The predicted cutting force components are in good agreement with experimental data over a wide range of cutting conditions. In particular, the effect of tool-nose radius and cutting parameters on chip geometry, cutting temperature, and cutting force components are studied. It is underlined that tool-nose radius promotes the increase in radial force, however, its influence on the other parameters is negligible.