Abstract

The finite element method is an important supplement to the experiment on the research of metal cutting mechanism. A 3D thermo-mechanical coupling model was established based on ABAQUS, in which a model of the tool with real structure and a simplified model of the work-piece based on the cutting zone were established. It can greatly improve the computational efficiency because the volume of the work-piece model can be reduced by 70% when compared with the traditional rectangle model. The validation shows that the prediction error of the cutting force is less than 15%, and the prediction results of the chip morphology are in good agreement with the experiment results. In order to reveal the mechanism of high speed milling of 6061-T6 Aluminum alloy, single factor experiments were carried out based on the established model. The results show that the cutting force and cutting temperature rapidly increase with the increase of the axial depth of cut a_p and the feed per tooth f_z, but slowly increase with the increase of the radial depth of cut a_e. The cutting force decreases with the increase of the spindle speed n. However, the cutting temperature increases with the increase of n firstly, and tends to be stable when n is over than 10,000 r/min.

摘要

有限元方法是对金属切削机理研究实验的重要补充。基于ABAQUS建立了三维热机械耦合模型，其中建立了具有真实结构的刀具模型和基于切削区的工件简化模型。与传统矩形模型相比，工件模型体积可减少70%，大大提高了计算效率。验证表明，切削力的预测误差小于15%，切屑形态预测结果与实验结果吻合较好。为了揭示6061-T6铝合金高速铣削的机理，在建立的模型基础上进行了单因素试验。a _p和每齿进给量f _z，但随着径向切深a _e的增加而缓慢增加。切削力随着主轴转速n的增加而减小。但切削温度首先随着n的增加而升高，当n大于10000r/min时趋于稳定。