Mechanistic Study And Process Optimization Of Cutting Edge Preparation By Magnetorheological Finishing

The cutting edge is a key component of the cutting tool and plays an important role in the machining process.After grinding with a grinding wheel,microscopic defects of varying degrees can be observed on the cutting edge of the tool under a microscope.Preparation of the cutting edge can effectively reduce micro defects on the surface of the cutting edge,making the surface of the cutting edge smoother,which is beneficial for improving the cutting performance of the cutting tool and prolonging its lifespan.At present,mainstream preparation methods such as brush preparation and drag type preparation for "hard hitting" solid-state grinding heads are difficult to accurately control the amount of material removed from the cutting edge,and the preparated cutting edge is prone to secondary damage.In response to the above issues,this project proposes a new approach to magnetorheological preparation of tool edges,mainly focusing on the following aspects:(1)Analysis of the magnetorheological preparation mechanism of tool edge.This article introduces the magnetorheological effect of magnetorheological preparation fluid under the action of a magnetic field,simulates the process of magnetorheological preparation fluid acting on the cutting edge using Fluent software,and analyzes the pressure and shear force on the surface of the cutting edge.Elaborate on the mechanism of tool edge magnetorheological preparation machining by analyzing the force acting on a single abrasive particle.And the effects of different parameters on the pressure and shear force on the surface of the cutting edge were studied.(2)Design and optimization of magnetorheological preparation device for cutting edge.Design and build a magnetorheological preparation device for the cutting edge of the cutting tool.Maxwell software is used to simulate and analyze the magnetic field generated by the magnetic field generator.Through the relationship between the viscosity of the MR preparation fluid and the magnetic flux density,the flow field simulation model of the MR preparation fluid with variable viscosity is established.Use Fluent software to simulate the flow field of magnetorheological preparation fluid and analyze the optimal preparation area of the tool edge.(3)Experimental study on magnetorheological preparation processing of tool edge.The preparation experiment was conducted on the cutting edge using the constructed magnetorheological preparation device,and the effect of magnetorheological preparation processing on the blunt radius and surface roughness of the cutting edge was studied.Preparation experiments were conducted using four parameters: different servo motor speed,magnetorheological preparation fluid ratio,current intensity,and abrasive particle size.The results showed that a good preparation effect can be achieved when the servo motor speed is1600 rpm,the magnetorheological preparation fluid ratio is 4:10,the current intensity is 8A,the abrasive particle size is W100,and the preparation time is 40-50 minutes.The removal of surface materials and improvement of surface quality on the cutting edge of the tool have been achieved,which has played a certain guiding role in the research of preparation processing technology for magnetorheological tool edges.