Research On Chipand Tool Wear Based On Finite Element Simulation

Metal cutting is one of the most important processes in mechanical manufacturing,metal cutting technology will directly affect the quality of processed workpiece,and then affect the quality of the product,therefore,the study of metal cutting processing plays an important role in improving the level of Chinese manufacturing industry.In the process of metal cutting,how to get the ideal chip and accurately know the tool wear directly affects the machining quality,crimp and chip flow angle,the section shape and size and relative position of the rake face and other factors directly affect the chip space motion chip,thus affecting the chip;wear how accurate the prediction tool is the guarantee of efficient machining.In this paper,research on two problems of chip and tool wear,determine its influencing factors,analysis of the formation and rupture of the chip to establish the prediction model of tool wear,cutting tool wear analysis and interaction.Effect of cutting tool wear and many factors,the need for a large number of experiments,is both time-consuming and cost,the finite element simulation technology is applied to the cutting process,which is to solve the cost problem and save time.In this paper,the finite element simulation software is established as a tool to establish a 2D and 3D cutting simulation model,and to study the two problems of chip and tool wear.First of all,the cutting parameters(cutting speed,cutting depth,feed rate)and cutter angle(front angle,angle and inclination angle)of such factors as the experimental variables,establish two-dimensional and three-dimensional simulation model,analysis of the formation mechanism of the factors,process and effect of chip,determine the chip flow angle size,regression analysis the establishment of angle of chip flow experience model using a multiple linear element.Secondly,analysis of the formation mechanism of chip movement,and then establish the mathematical model of chip movement,and carries on the solution,the chip up curl model,transverse curl model,mathematical model and the back angle of chip flow angle ofchip;analysis of the formation mechanism of chip breaking and chip crimp mechanism,the establishment of horizontal crimp type C chip breaking and spiral cutting mathematical model of chip breaking.Again,the classification,the tool wear causes,judgment and detection methods of analysis,analysis and Simulation of cutting force in metal cutting process,experiment and simulation results,the consistency of the experimental and simulation results,determine the cutting force factors;analysis of tool flank wear mechanism.The preset flank wear,the cutting simulation model,different cutting force flank wear under the size of the empirical model based on cutting force,the establishment of tool flank wear prediction model.Finally,the analysis of chip and tool wear interaction relations,determine the tool wear condition(blade wear,groove wear and tip wear)effect on the chip chip type relationship;analysis of the impact of changes in chip type of tool wear.Cutting conditions are determined based on the analysis of chip and tool wear.This paper takes the 45# steel as work-piece materials,the test blade is: the production of the Mitsubishi Co cutting processing with CVD coated super hard material US735 blade,the tool material is simulated to tool steel,cutting experiments were carried out in CA6140,the finite element simulation software ABAQUS to establish the simulation of two-dimensional and three-dimensional cutting model,using Johnson-Cook model as the constitutive model of the Johnson-Cook,the shear failure model as the failure criteria of materials,with the single factor experiments,multi factor orthogonal cutting tool wear debris and influence factors.