涂层硬质合金刀具切削钛合金仿真研究

采用Abaqus/Explicit显式有限元分析软件,通过建立不同膜厚以及不同的过渡层比例的涂层刀具,来进行正交切削TC4过程的计算机仿真。通过TC4钛合金材料的二维正交切削过程的仿真,得到并研究了切削过程中涂层刀具应力及温度的分布,同时通过对比不同膜厚以及不同的过渡层比例的涂层的刀具的模拟结果,系统地分析了涂层对切削过程主切削力的影响。此外,通过对有限元仿真的结果分析,为刀具涂层厚度及过渡层比例的优化,以及之后的刀具涂层制备实验工艺提供了重要参考。     

涂层硬质合金刀具切削Inconel718合金的有限元分析

采用Third Wave AdvantEdge切削仿真软件对Inconel 718合金进行车削有限元模拟,通过2D有限元模块分析了单层/多层涂层硬质合金刀具,在不同切削速度下的切削力、进给力和切削温度,以及涂层厚度对切削性能的影响,研究结果对新刀具材料和涂层的设计具有一定指导作用。     

20Cr钢的干切削性能研究

选用Ti N涂层YT15刀具和与之几何参数相同的未涂层YT15、YW2硬质合金刀具,利用单因素控制变量法改变切削用量参数对20Cr钢进行干切削试验,得到了三种刀具的切削试验结果,并对切削温度、切削力与切削用量之间的规律进行分析。在Deform-3D软件中建立20Cr钢的材料模型,对其切削过程进行仿真试验,比较并分析仿真值与试验值。结果表明:影响切削力的最大因素是背吃刀量,其次是进给量和切削速度;而影响切削温度的最大因素是切削速度,其次是进给量和背吃刀量;Ti N涂层能够有效降低切削过程中产生的切削力和切削温度;切削力仿真结果与试验数据的误差在2.1%-11.8%之间,验证了用有限元仿真软件对20Cr钢干切削切削力的预测是可行的。     

不同涂层刀具切削淬硬H13钢加工性能研究

为了研究不同涂层刀具切削淬硬H13钢的切削性能,进行了多层Ti化合物涂层、TiAlN涂层以及MTTiCN厚Al_2O_3TiN涂层材料刀具车削加工淬硬H13钢试验,分析了不同的涂层材料刀具与切削力、切削温度、涂层刀具磨损以及刀具寿命的关系。研究得出:多层Ti化合物涂层刀具受到三个方向的力都大于其它两种涂层的刀具,而且切削温度最高;用TiAlN涂层刀具切削时温度最低;切削过程中三种刀具后刀面磨损程度不同,发现多层Ti化合物涂层刀具磨损最为严重,寿命最短;MT-TiCN厚Al_2O_3Ti N涂层材料刀具比多层Ti化合物涂层刀具寿命长30%;TiAlN涂层刀具的切削寿命最长比多层Ti化合物涂层刀具寿命长45%。     

刀具涂层对42GrMo钢切削性能的影响研究

针对生产加工中采用较高切削速度切削直径和长度尺寸较大的42GrMo钢零件时刀具磨损严重的情况,运用DEFORM-3D有限元软件对42GrMo钢的切削过程进行仿真,得出TiN-Al2O3-TiCN复合层和Al2O3单层两种硬质合金涂层刀具对切削力和切削温度的影响。仿真结果表明采用TiN-Al2O3-TiCN涂层刀具的切削温度明显低于Al2O3涂层刀具,有利于提高刀具的耐用度。     

切削过程三维温度及热应力分析

建立了切削过程三维温度及热应力模型,整体模拟了金属的切削过程,得到不同切削速度下的切削力,工件变形区的应变、应力分布以及切削温度的分布,并对切削速度以及刀具前角对切削温度分布的影响进行分析.结果表明,提高切削速度对于减小主切削力,降低切削温度是有利的.三维仿真能更加真实地揭示刀具和工件的切削状态.     

涂层刀具切削淬硬H13模具钢的切削性能研究

基于有限元方法选取4种不同涂层材质的刀具进行切削淬硬H13模具钢仿真加工,研究涂层材质和切削速度对刀具切削性能的影响。从切削力和切削温度两个方面考虑,在相同切削条件下,Ti Al N涂层刀具的切削性能最优,Al_2O_3涂层刀具引起的已加工表面塑性变形最小;随着切削速度的提高,切削力和切削温度不断增加,工件材料已加工表面的塑性变形也逐渐增大。     

微织构刀具超声振动辅助加工切削性能仿真研究

对微织构刀具在超声振动辅助加工时的切削性能进行仿真研究。在研究中,在CAXA软件中建立刀具参数相同的二维刀具和微织构刀具,导入AdvantEdge软件,分别进行二维普通刀具切削、二维微织构刀具切削、二维普通刀具超声振动切削、二维微织构刀具超声振动切削,对比分析四种切削的仿真结果。通过仿真研究发现,微织构结构可以有效降低刀具温度,高温区域明显减小,同时可以减小刀具应力,减小高应力区域,对切削力的影响则不大。超声振动辅助加工可以有效减小切削力,降小刀具应力,对刀具温度的影响则不大。微织构结构和超声振动辅助加工同时作用,刀具温度最低,切削力和应力最小,并且可以延长刀具寿命。     

基于DEFORM的7075铝合金切削过程仿真研究

以7075铝合金为例,利用DEFORM仿真软件中的车削模块,建立铝合金切削有限元模型,对仿真结果进行分析,得到切削过程中切削力变化、工件应力及刀具表面切削温度分布等相关试验数据。通过切削力的测量试验验证仿真结果的有效性,结果表明仿真值与测量值的变化趋势一致,证明了仿真后处理结果的有效性。在此基础上研究刀具几何形状对切削过程的影响,该方法为生产实践中确定切削7075铝合金的刀具几何形状提供了新途径。     

考虑微刃口几何的Ti-6Al-4V钛合金加工切削力仿真预测与试验研究

切削刀具刃口半径对材料加工过程有着重要影响,其中如切削力、切削应力以及刀—屑交界面的温度分布,这些参数最终都会作用在刀具寿命和工件已加工表面完整性上。刀具刃口圆形钝化处理能够使刀具不易在切削过程中出现崩刃。本研究借助有限元方法对钝圆刃口刀具切削过程进行深入研究,其中有限元模型采用耦合欧拉—拉格朗日(Coupled Eulerian Lagrangian, CEL)方法建立。为研究刀具刃口对切削过程影响,本研究的切削工况包括四种刀具刃口半径(10μm, 20μm, 30μm, 40μm)和三种未变形切屑厚度(0.1mm, 0.15mm, 0.2mm),对12种工况分别进行仿真和试验研究,验证所提出的有限元模型的准确性和合理性。在此基础上,进一步对仿真结果中的切削温度、切削应力和材料流动状态等过程量进行深入分析研究发现,随着刀具刃口半径的增加,两向切削力的刃前切削应力和最高切削温度都呈增长趋势,最高切削温度由前刀面向后刀面移动。本研究或为钛合金切削过程的机理理解及难加工材料刀具和切削参数设计提供支持。     

基于DEFORM 3D的钛合金高速车削有限元仿真

应用DEFORM 3D软件对钛合金高速车削进行仿真研究,分析了不同切削参数下切削力和切削温度的规律,研究发现背吃刀量和进给量对主切削力的影响较大,切削力与主切削力变化基本一致,切削速度对主切削力的影响不明显,但后者对切削温度具有显著影响;研究了工件和刀具温度场的变化规律以及工件所受应力和刀具的磨损情况,发现最高温度出现在切削刃邻近2mm区域内,且温度最高处刀具磨损程度最大,工件最大应力在第一变形区和工件接触区邻近。     

陶瓷涂层刀具切削灰铸铁的试验研究

为了探究陶瓷涂层刀具涂层材质、基体材质对切削性能的影响,试验采用四种陶瓷涂层刀具连续干切削灰铸铁,测试了切削力和切削温度的变化情况以及后刀面的磨损量和已加工表面的粗糙度。结果表明,在刀具基体同为Si_3N_4的条件下,涂层材质为Ti N/Al_2O_3/Ti C的刀具比Ti N/Al_2O_3的切削性能好;在涂层材质同为Ti N的条件下,刀具基体Al_2O_3/Ti CN比Al_2O_3/Ti C的切削性能好。研究发现:四种陶瓷涂层刀具前刀面磨损形式均为微崩刃和月牙洼,后刀面磨损形式均为磨粒磨损和粘着磨损,涂层的磨损形式均为剥落和扩散磨损。     

Finite element modeling of micro-milling: Numerical simulation and experimental validation

In this study, micro-milling of Inconel 718 was investigated. For this purpose, cutting tests were conducted by using uncoated tools and taking four different feed rates (1.25, 2.5, 3.75, and 5 µm/flute) and a constant cutting velocity (48 m/min) into account. In numerical modeling, thermomechanical behavior was modeled using the modified Johnson–Cook material model. Analyses were also conducted for different cutting tool edge angles (+8°, 0, and ?8°). In the numerical analyses, cutting force, tool stress, and cutting temperature values were estimated depending on tool rotation and cutting tool edge type and compared with experimental results. When the results obtained from the study are considered, it is seen that the experimental cutting force and temperature values are in harmony with the numerical results. Moreover, it is seen that there is an increase in cutting force, cutting temperature, and stress values depending on the feed rate. In addition, in the numerical analyses for different cutting tool edge geometries it was observed that cutting force temperature and tool stress values varied depending on the edge geometries.     

Preparation and cutting performance of WS2 soft-coated tools

WS₂ soft-coated tools were produced by medium-frequency magnetron sputtering, multi-arc ion plating, and ion beam-assisted deposition technique on the cemented carbide YT15 (WC?+?15 % TiC?+?6 % Co) substrates. The thickness, microhardness, surface morphologies, crystallization, and coating/substrate critical load of the coatings were tested and investigated. Dry turning tests on no. 45 quenched and tempered steel were carried out with the coated tool and uncoated YT15 tool. Cutting forces and cutting temperatures were tested, respectively. The result shows that the cutting force of WS₂ soft-coated tool was decreased by 30–35 %, and the cutting temperature was reduced by 10–15 % in comparison with the uncoated YT15 tool. Through cutting force and cutting temperature theoretical analysis, the lower average shear strength of WS₂ soft coating at the tool–chip and tool–workpiece interfaces leads to the decrease of cutting force and cutting temperature during cutting process. The advantage in cutting force and cutting temperature is obvious in relatively high-speed and high-temperature conditions may be because of the high temperature resistance and the oxidation resistance of WS₂ soft coating which is not sensitive to high cutting temperature and high cutting speed.     

High-Speed Machining of Malleable Cast Iron by Various Cutting Tools Coated by Physical Vapor Deposition

The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched.In this paper,turning tests were conducted on cemented carbide tools with different coatings(a thick TiN/TiAlN coating,a thin TiN/TiAlN coating,and a nanocomposite(nc)TiAlSiN coating).All coatings were applied by physical vapor deposi-tion.In a comparative study of chip morphology,cutting force,cutting temperature,specific cutting energy,tool wear,and surface roughness,this study analyzed the cutting characteristics of the tools coated with various materials,and established the relationship between the cutting parameters and machining objectives.The results showed that in malleable cast iron machining,the coating material significantly affects the cutting performance of the tool.Among the three tools,the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force,the lowest cutting tempera-ture,least tool wear,longest tool life,and best surface quality.Moreover,in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions,the wear mechanism of the coated tools was found to depend on the cast iron being machined.Therefore,the performance requirements of a tool depend on multiple factors,and selecting an appropriately coated tool for a particular cast iron material is essential.     

微织构Al_2O_3-TiC陶瓷刀具切削性能仿真研究

前刀面有微织构的刀具与无织构刀具的切削性能不同。为了研究Al_2O_3-Ti C陶瓷刀具前刀面凹坑微织构分布对刀具切削性能的影响,使用ABAQUS对陶瓷刀具进行三维建模,将模型导入有限元分析软件Advantedge中,在相同条件下,对无微织构和有微织构刀具进行三维切削仿真,对比其切削力、切削温度及应力分布,结果表明,具有特定凹坑微织构参数的Al_2O_3-Ti C刀具在切削过程中可降低切削力,改善温度和应力分布。     

刀具涂层技术及涂层刀具切削性能的试验研究

在阐述刀具硬质涂层技术发展新动向的基础上,通过车削、铣削及攻丝的切削试验证明:涂层刀具的切削力总比未涂层刀具的小,且不同涂层刀具的切削力减小程度不同,在试验的几种涂层刀具中,AlTiN涂层、TiCN-WS2涂层刀具的切削力减小得多些.     

基于Deform 3D的刀具切削刃钝圆半径的优化设计

运用Deform 3D软件对考虑了刃口半径的切削过程进行了有限元仿真,分析了切削刃半径对加工过程对切削力和切削温度的影响。并对刀具应力及刀具磨损进行了分析,为刃口的优化设计提供了有力的依据。     

AISI1045钢切削仿真过程的研究

基于ABAQUS建立了AISI1045钢的二维切削仿真模型,分析了应力的分布规律,并通过改变刀具前角,研究了刀具前角对切削力和前刀面温度的影响.结果表明,刀具前角增大,切削力会随之减小,而刀具前刀面温度会随之增大.分析结果有利于刀具的选择.