切削加工过程数值模拟的研究进展

近年来,有限元方法在切削加工模拟中得到了越来越广泛的应用,在研究切削工艺参数及切屑成形机理方面有着不可替代的作用。本文介绍了国外切削加工过程有限元数值模拟的研究进展,阐述了切削过程有限元模拟的关键技术,包括切屑形成、切削加工中的热力耦合、工件与刀具接触和摩擦、切屑分离和断裂准则以及工件残余应力、残余应变的模拟等技术;最后,还对切削工艺有限元数值模拟的发展方向作了探讨。      

纳米尺度下切削过程的准连续介质力学模拟

采用准连续介质力学方法模拟了镍单晶体刀具在单晶铜工件上的切削过程,深入分析了切削过程中的能量演化?应力场变化和原子位移情况等因素.结合切削过程中位错滑移等塑性行为和原子径向分布理论,揭示了切屑产生的机理,证实了切削过程中已加工表面和体相晶体结构的非晶态变化是切屑产生的主要原因.通过对纳米切削过程不同阶段的模拟表明:刀具的耕犁作用下剪切带的形成和扩展是切屑形成的初始阶段;变质层的产生是纳米切削的中间阶段并构成了加工表面组织;储存在变形晶格中的变形能超过一定值时,晶格被打破,形成非晶态结构是切屑形成的最终阶段.     

切削力建模方法综述

航空航天工程广泛采用薄壁复杂结构零件, 实现其高效精密数控加工关键技术具有重大的现 实意义. 传统的CAD/CAM软件在确定切削策略和规划刀位轨迹时, 一般仅基于零件的理想几 何形状. 由于切削力引起的刀具、零件显著的加工变形即``让刀'现象, 必然导致零件的实 际加工表面与理论值之间存在较大偏差. 工程师往往不得不通过选用比较保守的切削用量和 多次重复精加工过程来保证零件的加工精度. 为了能够从根本上解决这一问题, 很有必要通 过建立准确的切削力预报模型, 仿真切削加工的物理过程, 揭示工件和刀具的加工变形规律, 补偿原始数控刀具轨迹, 最终达到改善工件加工精度和提高加工效率的目的. 本文综述了各 种不同的切削力建模方法, 包括基于切屑形成机理的二维正交切削力模型、基于单位切削力 系数的铣削力模型、神经网络模型以及模糊灰色理论等. 目的是为实现薄壁复杂结构零件的 加工变形预测控制、关键工艺参数优化以及加工过程的物理仿真提供理论基础.     

金属切屑塑性流动的稳定性

对金属正交切削过程中切屑形成机制和材料塑性流动行为进行实验研究和理论分析. 通过对4 种常用金属材料正交切削过程的实验研究和切屑形貌的微观观察,确定了连续切屑转变成锯齿切屑的临界速度. 结果表明该临界速度与材料性能相关. 在实验观察基础上,提出描述材料正交切削过程的二维分析模型. 该模型假设切屑形成区为包括主剪切区和次剪切区的一个平行四边形. 载荷有主剪切区中的剪应力和次剪切区中的正压力;通过量纲分析得到描述材料正交切削过程的无量纲主控参数和无量纲形式的基本控制方程;应用线性稳定性分析方法建立平面应变状态下评价材料塑性流动稳定性的普遍准则;求得切屑形成区内材料塑性变形的速度和应力近似解. 讨论切屑形成、形貌转变以及相关的塑性失稳机制. 分析结果表明, 表征材料惯性与阻尼之比的无量纲参数— 雷诺数可以作为主控参数描述金属切削过程以及切屑材料塑性流动的稳定性.      

金属切屑塑性流动的稳定性

对金属正交切削过程中切屑形成机制和材料塑性流动行为进行实验研究和理论分析.通过对4种常用金属材料正交切削过程的实验研究和切屑形貌的微观观察,确定了连续切屑转变成锯齿切屑的临界速度.结果表明该临界速度与材料性能相关.在实验观察基础上,提出描述材料正交切削过程的二维分析模型.该模型假设切屑形成区为包括主剪切区和次剪切区的一个平行四边形.载荷有主剪切区中的剪应力和次剪切区中的正压力;通过量纲分析得到描述材料正交切削过程的无量纲主控参数和无量纲形式的基本控制方程;应用线性稳定性分析方法建立平面应变状态下评价材料塑性流动稳定性的普遍准则;求得切屑形成区内材料塑性变形的速度和应力近似解.讨论切屑形成、形貌转变以及相关的塑性失稳机制.分析结果表明,表征材料惯性与阻尼之比的无量纲参数—雷诺数可以作为主控参数描述金属切削过程以及切屑材料塑性流动的稳定性.     

陶瓷刀具干切削等温淬火球铁(ADI)的磨损机理研究

采用陶瓷刀具(CC650)和YG6硬质合金刀具对等温淬火球墨铸铁(以下简称ADI)材料进行干式精车切削试验, 采用带有X射线能谱分析的扫描电子显微镜观察刀具磨损表面形貌, 用能谱仪对刀具磨损微区和工件表面成分进行分析, 用X射线衍射仪对刀具、 ADI材料和切屑等试样进行物相分析, 研究陶瓷刀具磨损形态及其磨损机理. 结果表明: 刀具磨损的主要形式为磨粒磨损、粘着磨损、 扩散磨损及微崩和脱落; ADI材料中含有微量Al和Ti元素, 在较高速度下切削ADI材料时, 刀具与工件之间的亲和性增加而导致粘着磨损; 在刀具前刀面平均切削温度大于800 ℃以上时,ADI材料中的元素Fe和Si扩散到刀面,刀具中的元素Al和Ti扩散到ADI材料表面,从而加剧刀具的磨损;切削后ADI材料表面出现的Al2O3相及切屑中的FeCr相等高硬度化合物颗粒是造成CC650刀具磨粒磨损的主要原因.     

PCBN刀具切削GH706磨损特征研究

本文中采用PCBN刀具对镍基高温合金GH706车削试验研究刀具磨损并对比刀具材料.首先观察PCBN刀具的磨损形貌,根据其位置、形态等特点进行分类,分别为主切削刃边缘崩刃、主切削刃微崩刃及后刀面磨损、主副切削刃交界后刀面磨损、副切削刃微崩刃及副后刀面磨损等,从而将PCBN刀具磨损形式进行全新的定义,并根据刀具、工件属性以及切削过程刀-屑-工件相互作用特点,分析了不同类型磨损形成的原因.然后研究刀具磨损形貌随切削进程的变化规律,揭示了PCBN刀具切削GH706的失效历程.最后对比了5种不同PCBN材料的刀具的前、后刀面磨损状态,得到了CBN含量、结合剂种类对刀具磨损的影响规律,为高效切削镍基高温合金用PCBN刀具设计及应用提供技术指导.     

冷却润滑对纯铁车削刀具磨损的影响机理

合适的冷却润滑方式是改善切削摩擦,降低切削温度和切削力,提高刀具寿命的关键技术.采用干切、水冷、微量润滑(Minimum quantity lubrication,MQL)以及菜籽油润滑等四种方式进行了不同工艺参数下纯铁材料的车削试验,研究了冷却润滑方式对纯铁车削刀具磨损的影响机理.结果表明:纯铁车削时刀具磨损形态以主、副切削刃处的沟槽磨损和后刀面磨损为主,前刀面上黏结有工件材料并形成积屑瘤;MQL条件下的刀具寿命最长,而水冷时最小;扩散磨损、氧化磨损和黏结磨损是纯铁车削刀具的主要磨损机理;四种冷却润滑方式下切削力、前刀面与切屑间平均摩擦系数和表面显微硬度的显著差异是造成刀具寿命明显不同的根本原因.     

陶瓷刀具切削区温度场的计算机模拟

在切削金属过程中所消耗的能量几乎９０％以上都转化为热，致使工件，切屑和刀具的温度都上升，其中刀具的温升与切削机理及切削参数密切相关，并且直接影响刀具磨损及其全用寿命。为了研究陶瓷刀具切削温度分布对其磨损规律和机理的影响，根据传热理论建立了数学模型，用计算机模拟编制出陶瓷刀具切削区温度场计算的专业软件，可以得出不同陶瓷料刀具在不同切削条件下切步同工件材料过程中的温度分布曲线图，而且实际测量值与模拟值     

正交切削过程的刚塑性有限元算法及其实现

对刚塑性有限元用于正交切削分析中的切屑与基体材料分离准则、切屑与前刀面脱离判据等关键技术问题进行了系统的研究;建立了求解该问题的刚塑性有限元基本方程,给出了单元刚度矩阵和节点载荷列阵的详细算法以及金属大变形过程中网格畸变问题的处理技术。利用自行开发的正交切削模拟计算程序,对铝合金ZL-301创削过程进行了全程模拟,计算结果与试验结果吻合。     

Surface waviness removed by orthogonal machine cutting

A thermoelastoplastic analysis is made to study the surface waviness of orthogonal machine cutting. As a workpiece experiences heavy cutting, chips are formed incrementally in a steady fashion leaving a sinusoidal wavy surface as evidence of the varying thickness of the uncut chips. The finite difference method is applied to determine the temperature distribution in the chip and tool while a large deformation thermoelastoplastic finite element analysis is made to simulate the wave removing process whereby the wavy surface is modelled by saw-tooth shaped meshes. Determined are the chip geometry, residual stresses in the machined surface, temperature distributions in the chip and tool forces. The cutting forces are also calculated and they agree well with the test results.     

Sn和Si含量对Al—Sn—Si合金室温压缩变形流变应力的影响

采用Gleeble-1500试验机，在室温和恒应变速率下，测定了Al-Sn-Si系合金压缩变形的流变应力曲线。结果表明，在Sn、Si含量分别为0－20和0－8wt．％的范围内，当Sn含量恒定时，流变应力随Si含量的增加而增加，而当Si含量恒定时，流变应力则随Sn含量的增加而略有降低；从Al-Sn-Si，Al-Si及Al-Sn 合金流变应力曲线的差异，分析了Sn和Si对合金塑性变形过程的影响机制。     

Mechanical behavior of Gamma-Met PX under uniaxial loading at elevated temperatures and high strain rates

Gamma titanium aluminides have received considerable attention over the last decade. These alloys are known to have low density, good high temperature strength retention and good oxidation and corrosion resistance. However, poor ductility and low fracture toughness have been the key limiting factors in the full utilization of these alloys. More recently, a new generation of gamma titanium aluminide alloys, commonly referred to as Gamma-Met PX, has been developed by GKSS, Germany. These alloys have been observed to have superior strength and better oxidation resistance at elevated temperatures when compared with conventional gamma titanium aluminides.The present paper discusses results of a study to understand the uniaxial mechanical behavior in both compression and tension of Gamma-Met PX at elevated temperatures and high strain rates. The compression and tensile tests are conducted using a modified Split-Hopkinson Bar apparatus at test temperatures ranging from room temperature to 900 °C and strain rates of up to 3500 s⁻¹. Under uniaxial compression, in the temperature range from room to 600 °C, the flow stress is observed to be nearly independent of test temperature. However, at temperatures higher than 600 °C thermal softening is observed at all strain rates with the rate of thermal softening increasing dramatically between 800 and 900 °C. The room temperature tensile tests show negligible strain-rate dependence on both yield stress and flow stress. With an increase in test temperature from room to 900 °C, the material shows a drop in both yield and flow stress at all levels of plastic strain. However, the measured flow stress is still higher when compared to nickel based super-alloys and other gamma titanium aluminides under similar test conditions. Also, no anomaly in yield stress is observed up to 900 °C.     

Adiabatic shear banding and scaling laws in chip formation with application to cutting of Ti–6Al–4V

The phenomenon of adiabatic shear banding is analyzed theoretically in the context of metal cutting. The mechanisms of material weakening that are accounted for are (i) thermal softening and (ii) material failure related to a critical value of the accumulated plastic strain. Orthogonal cutting is viewed as a unique configuration where adiabatic shear bands can be experimentally produced under well controlled loading conditions by individually tuning the cutting speed, the feed (uncut chip thickness) and the tool geometry. The role of cutting conditions on adiabatic shear banding and chip serration is investigated by combining finite element calculations and analytical modeling. This leads to the characterization and classification of different regimes of shear banding and the determination of scaling laws which involve dimensionless parameters representative of thermal and inertia effects. The analysis gives new insights into the physical aspects of plastic flow instability in chip formation. The originality with respect to classical works on adiabatic shear banding stems from the various facets of cutting conditions that influence shear banding and from the specific role exercised by convective flow on the evolution of shear bands. Shear bands are generated at the tool tip and propagate towards the chip free surface. They grow within the chip formation region while being convected away by chip flow. It is shown that important changes in the mechanism of shear banding take place when the characteristic time of shear band propagation becomes equal to a characteristic convection time. Application to Ti–6Al–4V titanium are considered and theoretical predictions are compared to available experimental data in a wide range of cutting speeds and feeds. The fundamental knowledge developed in this work is thought to be useful not only for the understanding of metal cutting processes but also, by analogy, to similar problems where convective flow is also interfering with adiabatic shear banding as in impact mechanics and perforation processes. In that perspective, cutting speeds higher than those usually encountered in machining operations have been also explored.     

Plastic behavior of a nickel-based alloy under monotonic-tension and low-cycle-fatigue loading

The plastic behavior of an annealed HASTELLOY^® C-22HS™ alloy, a face-centered cubic (FCC), nickel-based superalloy, was examined by in-situ neutron-diffraction measurements at room temperature. Both monotonic-tension and low-cycle-fatigue experiments were conducted. Monotonic-tension straining and cyclic-loading deformation were studied as a function of stress. The plastic behavior during deformation is discussed in light of the relationship between the stress and dislocation-density evolution. The calculated dislocation-density evolution within the alloy reflects the strain hardening and cyclic hardening/softening. Experimentally determined lattice strains are compared to verify the hardening mechanism at selected stress levels for tension and cyclic loadings. Combined with calculations of the dislocation densities, the neutron-diffraction experiments provide direct information about the strain and cyclic hardening of the alloy.     

微织构刀具正交切削Ti6Al4V的试验研究

仿生摩擦学的出现,为刀具减摩技术提出了新的研究方向,通过钛合金的正交切削试验研究了表面微织构刀具在微量润滑和无润滑剂条件下的减摩性能.结果表明：表面微沟槽在润滑剂条件下可以有效地改善刀屑之间的摩擦,降低切削力与切削温度,同时表面微沟槽还可以改善钛合金的粘结现象;在无润滑剂条件下,微沟槽依然具有一定的＂润滑＂作用.     

Three-dimensional elastic–plastic finite element analysis for orthogonal cutting with discontinuous chip of 6-4 brass

An elastic–plastic finite element model is developed for 3D orthogonal cutting of discontinuous chips. The tool is P20 while the workpiece is made of 6-4 brass. Examined under the condition of low cutting speed are the initial crack location, the direction of crack growth and variations of discrete chips. These predictions are made possible by application of the strain energy density (SED) theory. The initial crack was formed above the tool tip and grew progressively along the stationary values of the SED function until the trajectory intersects with the free surface. The plastic deformation and friction result in a high equivalent stress in the secondary deformation zone of the first longitudinal chip. Stresses are also high at the location of crack initiation. The chip node near the tool face is sensitive to the contact of the tool face. As more residual stress prevails after the first longitudinal cut, degradation of the workpiece surface prevails and should be accounted for.     

摩擦系数对钛合金等通道转角挤压影响的有限元分析

以Ti-6Al-4V钛合金高温变形行为研究为基础,建立了等通道转角挤压（ECAE）的三维模型,运用DEFORM-3D有限元分析软件模拟了600 ℃等温条件下不同摩擦系数对Ti-6Al-4V合金ECAE过程中的温度场,等效应力,等效应变以及等效应变率的影响。结果表明：核心高温区以及核心应力区主要集中于转角处;随着摩擦系数增大,核心高温区面积增大,转角入口区的应力也有所增加;点迹跟踪结果表明各点应变均在经过转角处达到最大值,内角点及外角点处的变形较不稳定。     

Measurements of Forces and Temperature Fields in High-Speed Machining of 6061-T6 Aluminum Alloy

This study focuses on experimental modeling of dry high-speed machining at 30 m/s cutting velocity using 6061-T6 aluminum alloy. A modified Hopkinson bar apparatus is employed to simulate orthogonal machining, a focused array of mercury–cadmium–tellurium infrared detectors is used to measure the temperature distribution around the tool tip, and a three-component quartz force transducer is utilized in measuring the cutting and feed forces. The resulting measurements confirm the assumption of steady-state cutting and allow for estimation of the partition of cutting work into heating, shear, and momentum changes in the chip. In an earlier study, measurements of temperature distributions showed little heating of the finished surface. Therefore, a study of the temperature fields generated during machining with a cutting tool that has a wear-land was performed. The wear-land contributes significantly to the heating of the workpiece and, at this speed, is the most likely mechanism for the generation of residual stresses and a temperature rise on the finished surface.