基于正交切削模型的铣削加工残余应力预测方法

提出了一种基于正交切削模型的铣削加工残余应力预测方法.针对直齿圆柱铣刀建立了铣削加工的平面应变有限元模型,并通过分段曲线限定不同温度下应力与应变间的关系,详细表明材料的加工硬化规律.有限元模型采用相关的实验数据进行了验证.在铣削用量确定的前提下,通过对航空铝合金70507451进行加工模拟,研究了直齿圆柱铣刀前角对已加工表面残余应力的影响.

The optimizing method of milling tool normal rake based on orthogonal cutting process simulation

Based on large deformation theory and virtual work principle, a thermo-elastic-plastic finite element equation for simulating the metal orthogonal cutting process was approached. Under a certain assumptions a coupled thermo-mechanical model was constructed with regard to plain strain orthogonal metal cutting. In addition, several special finite element techniques, such as the chip separation criteria, friction model, have been implemented to improve the accuracy and efficiency of the finite element simulation. A chip separation criterion based on stress failure and geometry was adopted to realize separation of twin nodes. To obtain optimizing tool life, some cases with different tool normal rake were covered based on the constant condition of milling parameter. Comparing the results of simulation, the optimizing tool normal rake was gained. Furthermore, the optimizing material removal rate was obtained by changing cutting conditions.