Numerical Simulation And Analysis Of High Speed Metal Machining

High speed machining technology is featured with high cutting speed, high feed rate, and high precision. Since this concept came out, a lot of attentions were attracted, and many researches were made on it. But compared to traditional machining, the investigations on high speed cutting are underway. The existed researches show that it is effective to investigate high speed cutting using numerical method. In this way, not only the disadvantages of the experiments can be conquered, the chip formation, cutting forces, temperature, strains, strain rates, etc in the processes of machining can also be predicted quantitatively. Besides, numerical method is significant in saving time and sources, improving the precisions.Based on metal cutting theories, the finite element models and solutions of high speed metal machining were first discussed. And the important technology of high speed cutting modeling was summarized, including the establishment of finite element equations, flow stress models of workpiece materials, methods to building up element grids, chip separation criteria, material fracture criteria, the contact friction model, the generation of heat and distributions of the temperature, residual stresses and strains. Then an orthogonal cutting model was established, and the processes of metal cutting were modeled effectively under different cutting speeds using the sliding-sticking friction model. The analysis of the effect of cutting speed on the machining processes was given. Good agreement is achieved between the simulation results and the experimental results. On this base, a hardness-based flow stress model was set up and the serrated chip formation was simulated, and the mechanisms of the serrated chip formation were revealed. Further more, the distributions of the residual stress were modeling under different friction coefficients and the effect of friction condition was analyzed. Then a wear model was built, and the wear of the cutter was predicted under normal and high cutting speed. Finally the cutter parameters were investigated by modeling the cutting processes using different rake angle and cutting edge. Moreover, the effects of the coated and uncoated tool were compared. And the conclusions were consistent with the experiment.This paper investigated the mechanism of the high speed metal machining using numerical method. By analyzing and comparing the results, the feasibility of the numerical simulation was validated, and valuable conclusions were provided for the engineering applications.