Research On The Finite Element Simulation And Experiment In The Cutting Process Of Alumina Matrix Self-lubricating Ceramic Tool

Self-lubricating ceramic tool material refers to the tool material with the addition of solid lubricants which makes the tool have anti-friction and anti-wear properties,so that it is helpful to improve the tool’s performance and cutting precision.It also can solve some problems appears in the machining process such as gross error,low precision and short tool life and so on,avoid the environmental pollution and the misuse of resources caused by multiple tool change,and then promote the sustainable development of industry process fundamentally.This thesis lists and introduces five kinds of finite element software.The author chose the DEFORM software to make the finite element analysis of Al₂O₃/TiC/CaF₂ self-lubricating ceramic tool materials and study the cutting performance after the material made into cutting tools,so that the final results will be more scientific and rigorous.Meanwhile,the author also introduces and studies the constitutive equations and the heat conduction equations of this kind of tool materials.Based on it,the author also studies tool-chip friction types of the cutting tool,and describes the scientific simplifying means of modeling complex data with the MESH method.In addition,the author also studies on the physical properties of the material,analyses and calculates the main parameters and establishes orthogonal cutting model.This thesis simulates the cutting process of self-lubricating ceramic cutting tool when machining 45# steel and analyzes the distribution of cutting temperature and cutting force.It is deemed that when cutting temperature are near of 504℃,the solid lubricant CaF₂ will turn from being brittle to being plastic,then the cutting tool material will reduce friction and increase the lubricating effect.At the same time,the author also describes the causes of these effects and impacts.The author analyzes and researches the Al₂O₃/TiC/CaF₂ self-lubricating ceramic cutting tool material from the perspective of influencing factors in the cutting process,including cutting speed,depth of cut and the rake angle.The results show that the higher the cutting speed is,the higher the temperature near the cutting edge becomes,and the cutting force fluctuates.When the depth of cut is 0.2mm,0.3mm,0.4mm and 0.5mm respectively,the bigger the depth of cut is,the higher the temperature near the cutting edge becomes,but it does not increases in proportion with material cutting amount.It is deemed that the cutting force of γ =-8° are close to that of γ=-5°,and the smaller the rake angle is,the lower the cutting temperature becomes.At the end of this thesis,the author conducts dry cutting tests with the Al₂O₃/TiC/CaF₂ self-lubricating ceramic cutting tool.When cutting 45# steel,the flank wear increases in proportion with the cutting speed.The wear mechanism under lower cutting speed is manly abrasive wear.The wear mechanism under higher cutting speed is manly abrasive wear combined with adhesive wear.The solid lubricant CaF₂ concentrates and smears on tool-chip contact area of the rake face,exhibiting self-lubricating effect.Cutting temperature and cutting force rise with increase of the cutting speed and the depth of cut,which is the same changing trend with the cutting simulation results.