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刀具磨损是车削加工淬硬钢等硬质材料过程中一直存在的一个难题,因而对刀具磨损和刀具寿命的进行定量预测具有重要的意义。建立了车削加工过程刀具磨损预测模型,并对该模型进行仿真分析和实验验证。以前的相关研究在分析刀具磨损的大小和位置时,大都是基于磨粒磨损、缺陷扩散或黏着磨损等机理建立单一的数学模型,预测结果会有较大的偏差。为了克服此缺陷,综合考虑磨粒磨损、缺陷扩散及黏着磨损等三种刀具磨损机理的影响,采用了一种新的刀具磨损预测耦合模型。然后将建立的磨损模型导入到有限元分析软件Deform-3D中,并对车削淬硬钢的加工过程进行模拟,分析中刀具的磨损规律;最后选用CBN刀具车削AISI 1045号淬硬钢进行实验研究,验证和评估预测模型的可靠性。结果表明,实验与仿真分析的结果具有很好的一致性,预测模型是可靠和有价值的。
Tool wear is a difficult problem in the turning process of hardened steel and other hard materials. Therefore, it is of great significance to quantitatively predict tool wear and tool life. The tool wear prediction model of turning machining process is established, and the simulation analysis and experimental verification of the model are carried out. In the past, the related researches mainly analyzed the size and position of tool wear, and established a single mathematical model based on the mechanism of abrasive wear, defect diffusion or adhesive wear. The prediction results would be greatly deviated. In order to overcome this defect, a new tool wear prediction coupling model was adopted considering the wear mechanism of three kinds of tools, such as abrasive wear, defect diffusion and adhesive wear. Then, the established wear model was imported into the finite element analysis software Deform-3D. The machining process of turning hardened steel was simulated and the wear law of the tool was analyzed. Finally, the CBN tool was used to cut AISI 1045 hardened steel , Verify and evaluate the reliability of the forecasting model. The results show that the experimental and simulation results are in good agreement and the prediction model is reliable and valuable.