三维复杂槽型铣刀片粘结破损机理及破损判据的研究
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摘要
刀具破损和刀具磨损一样,也是刀具失效的一种形式。刀具在一定的切削条件下使用时,如果它经受不住强大的应力(切削力或热应力)冲击,就可能发生突然损坏,使刀具提前失去切削能力,这时刀具就发生了破损。本文针对铣削加工时,刀具粘结破损严重的问题,对三维复杂槽型铣刀片的粘结破损机理进行了深入系统的理论和试验研究。
首先,通过改进现有的铣削力、铣削温度动态测量系统,实现对铣刀片的铣削力、铣削温度的同时测量。对不同槽型铣刀片进行了三水平四因素的粘结破损正交试验,分析铣刀片的粘结破损与铣刀片的铣削力、铣削温度之间存在的联系,对正交试验结果进行极差分析、方差分析,得出影响铣刀片粘结破损寿命的显著性因素,为优化切削过程奠定了理论基础。
其次,对发生破损的刀片,借助扫描电镜观察了破损区域形貌,探讨了不同切削条件下、不同槽型铣刀片的粘结破损的产生机理。采用高速摄影的先进手段,对铣刀片发生粘结破损的整个切削过程进行了摄像,使对破损过程的观察更为真实、直观。
再次,依据试验得出的温度时间关系曲线,建立边界条件,采用大型有限元分析软件ANSYS对铣刀片的粘结破损区域进行了有限元分析,得出了铣刀片切入、切出时刻粘结破损区域的三维铣削温度场的分布情况。
最后,通过对铣刀片粘结破损机理的分析,得出了影响铣刀片粘结破损的多种因素,依据这些因素对铣刀片的粘结破损进行了判定,实现了对铣刀片粘结破损情况的预测,同时,对切削参数以及刀片几何参数提出了优化目标。考虑多种因素对铣刀片粘结破损的影响,对不同槽型铣刀片的抗粘结破损性能进行了综合评价,建立了铣刀片抗粘结破损性能的评判准则。
这些研究为三维复杂槽型铣刀片的进一步优化重构提供了抗粘结破损的理论依据。
The failure of cutting is same as the wear of cutting tool, which also is one kind of form which the cutting tool expires. Cutting tool is used when the certain cutting condition, if it cannot undergo the formidable stress (cutting force or thermal stress), can be possibly destroyed suddenly, causes the cutting tool lose the cutting power ahead, while happened failure. This paper aimed at the serious Sticking Failure problem during milling, theory and experiment are studied comprehensively and profoundly for the Sticking Failure Mechanism of the milling insert with 3D complex groove.
First, through improving existing 3D milling force and milling temperature dynamic measurement system, measured the milling force and milling temperature at the same time. Carried on orthogonal experiment of three levels and four factors to the different groove milling inserts, analyzed the connection between milling force, milling temperature and the Sticking Failure of milling insert. Carried on the variance analysis and extreme different analysis to the orthogonal experiment result, obtained the remarkable factors which affect the life of the Sticking Failure of milling insert, provided that the correct direction for optimizing cutting process.
Secondly, observed the appearance of failure region of the failed inserts aided by the scan electron microscope, and discussed the Sticking Failure Mechanism in different circumstances and milling inserts with different groove. Made use of the high speed camera which is an advanced method, recorded the entire cutting process which the milling insert happened Sticking Failure, made the observing of the failure process became truer and more ocular.
Thirdly, according to the temperature and time relation curve that got from the experiment, established the boundary conditions, adopting the large scale finite element analysis software ANSYS to analyze the failure region of the milling insert. Got the 3D milling temperature field on the failure region, when the milling insert cut in and out of the workpiece.
Finally, through analyzing the Sticking Failure Mechanism of milling insert,
首先,通过改进现有的铣削力、铣削温度动态测量系统,实现对铣刀片的铣削力、铣削温度的同时测量。对不同槽型铣刀片进行了三水平四因素的粘结破损正交试验,分析铣刀片的粘结破损与铣刀片的铣削力、铣削温度之间存在的联系,对正交试验结果进行极差分析、方差分析,得出影响铣刀片粘结破损寿命的显著性因素,为优化切削过程奠定了理论基础。
其次,对发生破损的刀片,借助扫描电镜观察了破损区域形貌,探讨了不同切削条件下、不同槽型铣刀片的粘结破损的产生机理。采用高速摄影的先进手段,对铣刀片发生粘结破损的整个切削过程进行了摄像,使对破损过程的观察更为真实、直观。
再次,依据试验得出的温度时间关系曲线,建立边界条件,采用大型有限元分析软件ANSYS对铣刀片的粘结破损区域进行了有限元分析,得出了铣刀片切入、切出时刻粘结破损区域的三维铣削温度场的分布情况。
最后,通过对铣刀片粘结破损机理的分析,得出了影响铣刀片粘结破损的多种因素,依据这些因素对铣刀片的粘结破损进行了判定,实现了对铣刀片粘结破损情况的预测,同时,对切削参数以及刀片几何参数提出了优化目标。考虑多种因素对铣刀片粘结破损的影响,对不同槽型铣刀片的抗粘结破损性能进行了综合评价,建立了铣刀片抗粘结破损性能的评判准则。
这些研究为三维复杂槽型铣刀片的进一步优化重构提供了抗粘结破损的理论依据。
The failure of cutting is same as the wear of cutting tool, which also is one kind of form which the cutting tool expires. Cutting tool is used when the certain cutting condition, if it cannot undergo the formidable stress (cutting force or thermal stress), can be possibly destroyed suddenly, causes the cutting tool lose the cutting power ahead, while happened failure. This paper aimed at the serious Sticking Failure problem during milling, theory and experiment are studied comprehensively and profoundly for the Sticking Failure Mechanism of the milling insert with 3D complex groove.
First, through improving existing 3D milling force and milling temperature dynamic measurement system, measured the milling force and milling temperature at the same time. Carried on orthogonal experiment of three levels and four factors to the different groove milling inserts, analyzed the connection between milling force, milling temperature and the Sticking Failure of milling insert. Carried on the variance analysis and extreme different analysis to the orthogonal experiment result, obtained the remarkable factors which affect the life of the Sticking Failure of milling insert, provided that the correct direction for optimizing cutting process.
Secondly, observed the appearance of failure region of the failed inserts aided by the scan electron microscope, and discussed the Sticking Failure Mechanism in different circumstances and milling inserts with different groove. Made use of the high speed camera which is an advanced method, recorded the entire cutting process which the milling insert happened Sticking Failure, made the observing of the failure process became truer and more ocular.
Thirdly, according to the temperature and time relation curve that got from the experiment, established the boundary conditions, adopting the large scale finite element analysis software ANSYS to analyze the failure region of the milling insert. Got the 3D milling temperature field on the failure region, when the milling insert cut in and out of the workpiece.
Finally, through analyzing the Sticking Failure Mechanism of milling insert,
引文
1 熊四昌.基于计算机视觉的刀具磨损状态监测技术的研究.浙江大学博士论文,2003
2 沈壮行.国内外工具市场的运行态势和若干思考.工具技术,2004,38(9):34~37
3 A. G. Mamalis, J. Kundrák and M. Horváth. Wear and Tool Life of CBN Cutting Tools. Int. J. of Adv. Manuf. Technol., 2002, 20: 475~479
4 董丽华,许小村.数控铣刀 CAD/CAE/CAM 技术.黑龙江科学技术出版社,2002:76~82
5 赵炳桢.切削技术与刀具工业的新时代.工具技术,2004,38(9):24~26
6 刘洁华,杨雁.金属切削刀具技术现状及其发展趋势展望.中国机械工程,2001,12(7):835~838
7 程伟.切削加工和刀具技术的现状与发展.工具展望,2002,36(123):3~6
8 沈壮行.入世之后我国工具企业面临的真正挑战及其对策.工具技术,2002,36(1):6~8
9 骆红云,梁淑卿,韩莲英.国内外新型刀具材料的发展现状.吉林工学院学报,2001,22(1):56~58
10 万珍平.限制接触刀具切削力与刀-屑接触长度关系的研究.工具技术,2002,36(9):15~17
11 中山一雄.金属切削加工理论.机械工业出版社,1985
12 熊烽,宾鸿赞.复杂形状刀具设计的三维可视化.工具技术,2002,36(4):18~22
13 董丽华.三维槽型刀片面铣刀切削机理及其 CAD/CAM 的研究.哈尔滨工业大学博士论文,1999
14 谭光宇.硬质合金刀具断续切削切出破损的研究.哈尔滨科技大学硕士论文,1989
15 刘广军.三维复杂槽型铣刀片虚拟设计.哈尔滨理工大学硕士论文,2004
16 刘战强,黄传真,万熠,艾兴.切削温度测量方法综述.工具技术,2002,36(3):3~6
17 郭强,谭光宇,董丽华等.三维复杂槽型铣刀片铣削平均温度数学模型.哈尔滨理工大学学报,2002,5(6):33~36
18 李兆坤,谭光宇,刘广军.面铣铣削力试验分析及受力密度函数研究.机械设计与研究,2004,20(4):57~58
19 张林鍹,童秉枢.并行工程中的装配仿真系统及其关键技术研究.计算机辅助设计与图形学报,1999,11(2):163~166
20 Bernard Nadel. Machining Software & Controls Supplement: Seats Knowledge. Cutting Tool Engineering, 1997, 49(5): 52~56
21 孙凤莲,李振加,陈波.切削 2.25Cr-1Mo 钢刀-屑间的粘焊破损机理.哈尔滨理工大学学报,1997,5(2):1~3
22 张闰红.三维复杂槽型铣刀片受力密度函数及应力场的研究.哈尔滨理工大学硕士论文,2004,3
23 郑敏利,李振加等.三维复杂槽型铣刀片铣削力的数学模型.制造技术与机床,2000,417(5):49~53
24 刘广军,谭光宇,刘美娟,李建平.波形刃铣刀片铣削温度试验分析.工具技术,2003,39(8):22~25
25 赵选民等.数理统计.第二版.西北工业大学出版社,2002
26 白新桂.数据分析与试验优化设计.清华大学出版社,1989
27 丁承民,张传生,刘贵忠.利用正交试验法优化配置遗传算法参数[J].西安交通大学学报,1997,31(9):81~87
28 李健华,王永录.用正交试验法进行多因素敏感性分析[J].技术经济,1995(7):59~61
29 C E Leshock, Y C Shin. Investigation on cutting temperature in turning by a tool-work thermocouple technique. Transaction of the ASME, Journal of Manufacturing Science and Engineering , 1997, 119(11): 502~508
30 Fenglian, Sun. Adhering Wear Mechanism of Cemented Carbide Cutter in the Intervallic Cutting of Stainless Steel Wear. 1998, (214): 79~82
31 Guangyu Tan, Julong Yuan, Xinlong Wang. Cause of brittle tool exit failure in intermittent cutting. Journal of Harbin Institute Technology, 1997, 4(2) :107~111
32 陆剑中.金属切削原理与刀具.机械工业出版社,2004
33 Z. Klim, Cutting tool reliability analysis for variable feed milling of 17-4PH stainless steel. Wear. 1996, 195: 206~213
34 Z.J. Li, G.Y. Tan, Y.B. Wang, Y.M. Rong. A Rise in Temperature by Moving Planar Sources of Heat on the Rake Face for the Waved-edge Milling Inserts. Key Engineering Materials, 2004, 259~260: 342~346
35 P. Srinivasa Pai, T. N. Nagabuhshana, P. K. Ramakrishna Rao. Flank Wear Estimation in Face Milling Based on Radial Basis Function Neural Networks. Int. J. of Adv. Manuf. Technol., 2002, 20: 241~247
36 Barry, Byrne. Cutting tool wear in the machining of hard steels Wear, 2001, 27(6): 782~788.
37 X. D. Fang, D Zhang, An investigation of adhering layer formation during tool wear progression turning of free-cutting stainless steel Wear. 1996, 197: 169~178
38 达世亮.汽车工业切削与刀具技术现状.工具技术,2004,38(9):38~42
39 韩荣第,周明.金属切削原理与刀具.哈尔滨工业大学出版社,1998
40 孙有社,尤伦超.国内外刀具材料的发展与应用前景.机械工程师,2002,(3):10~12
41 刘孝敏.工程材料的为细观结构合力学性能.中国科学技术出版社,2003
42 李兆坤.三维复杂槽型铣刀片应力场分析及评价.哈尔滨理工大学硕士论文,2005
43 T.I.El-Wardany, E.Mohammed and M.A.Elbestawi. Cutting Temperature of Ceramic Tools in High Speed Machining of Difficult-to-Cut Materials. Journal of Manufacturing Science and Engineering. 1999, l(8): 121~501
44 王凤丽.三维复杂槽型铣刀片温度场可视化及评价准则研究.哈尔滨理工大学硕士论文,2003
45 H. Huang., Y.C. Liu. Experimental investigations of machining characteristics and removal mechanisms of advanced ceramics in high speed deep grinding. International Journal of Machine Tools & Manufacture, 2003, 43: 811~823
46 Mackawa K. Finite element analysis of behavior in metal machining. International Journal of JSME, Series C, 1996, 39(4): 864~870
47 王玉斌.三维槽型铣刀片受热密度函数与温度场数学模型的研究.哈尔滨理工大学硕士论文,2005,3
48 周泽华.金属切削理论.机械工业出版社,1992:62~91
49 张万洪.硬质合金断续切削时的破损分析.工具技术,2002,36(4):15~18
50 周忆.超高速铣削加工技术研究.重庆大学博士论文,2004
51 陈爱弟,王信义,王忠民,杨大勇,贾玉平.基于模糊聚类的刀具磨损量在线监测方法.北京理工大学学报,2000,20(3):276~280
2 沈壮行.国内外工具市场的运行态势和若干思考.工具技术,2004,38(9):34~37
3 A. G. Mamalis, J. Kundrák and M. Horváth. Wear and Tool Life of CBN Cutting Tools. Int. J. of Adv. Manuf. Technol., 2002, 20: 475~479
4 董丽华,许小村.数控铣刀 CAD/CAE/CAM 技术.黑龙江科学技术出版社,2002:76~82
5 赵炳桢.切削技术与刀具工业的新时代.工具技术,2004,38(9):24~26
6 刘洁华,杨雁.金属切削刀具技术现状及其发展趋势展望.中国机械工程,2001,12(7):835~838
7 程伟.切削加工和刀具技术的现状与发展.工具展望,2002,36(123):3~6
8 沈壮行.入世之后我国工具企业面临的真正挑战及其对策.工具技术,2002,36(1):6~8
9 骆红云,梁淑卿,韩莲英.国内外新型刀具材料的发展现状.吉林工学院学报,2001,22(1):56~58
10 万珍平.限制接触刀具切削力与刀-屑接触长度关系的研究.工具技术,2002,36(9):15~17
11 中山一雄.金属切削加工理论.机械工业出版社,1985
12 熊烽,宾鸿赞.复杂形状刀具设计的三维可视化.工具技术,2002,36(4):18~22
13 董丽华.三维槽型刀片面铣刀切削机理及其 CAD/CAM 的研究.哈尔滨工业大学博士论文,1999
14 谭光宇.硬质合金刀具断续切削切出破损的研究.哈尔滨科技大学硕士论文,1989
15 刘广军.三维复杂槽型铣刀片虚拟设计.哈尔滨理工大学硕士论文,2004
16 刘战强,黄传真,万熠,艾兴.切削温度测量方法综述.工具技术,2002,36(3):3~6
17 郭强,谭光宇,董丽华等.三维复杂槽型铣刀片铣削平均温度数学模型.哈尔滨理工大学学报,2002,5(6):33~36
18 李兆坤,谭光宇,刘广军.面铣铣削力试验分析及受力密度函数研究.机械设计与研究,2004,20(4):57~58
19 张林鍹,童秉枢.并行工程中的装配仿真系统及其关键技术研究.计算机辅助设计与图形学报,1999,11(2):163~166
20 Bernard Nadel. Machining Software & Controls Supplement: Seats Knowledge. Cutting Tool Engineering, 1997, 49(5): 52~56
21 孙凤莲,李振加,陈波.切削 2.25Cr-1Mo 钢刀-屑间的粘焊破损机理.哈尔滨理工大学学报,1997,5(2):1~3
22 张闰红.三维复杂槽型铣刀片受力密度函数及应力场的研究.哈尔滨理工大学硕士论文,2004,3
23 郑敏利,李振加等.三维复杂槽型铣刀片铣削力的数学模型.制造技术与机床,2000,417(5):49~53
24 刘广军,谭光宇,刘美娟,李建平.波形刃铣刀片铣削温度试验分析.工具技术,2003,39(8):22~25
25 赵选民等.数理统计.第二版.西北工业大学出版社,2002
26 白新桂.数据分析与试验优化设计.清华大学出版社,1989
27 丁承民,张传生,刘贵忠.利用正交试验法优化配置遗传算法参数[J].西安交通大学学报,1997,31(9):81~87
28 李健华,王永录.用正交试验法进行多因素敏感性分析[J].技术经济,1995(7):59~61
29 C E Leshock, Y C Shin. Investigation on cutting temperature in turning by a tool-work thermocouple technique. Transaction of the ASME, Journal of Manufacturing Science and Engineering , 1997, 119(11): 502~508
30 Fenglian, Sun. Adhering Wear Mechanism of Cemented Carbide Cutter in the Intervallic Cutting of Stainless Steel Wear. 1998, (214): 79~82
31 Guangyu Tan, Julong Yuan, Xinlong Wang. Cause of brittle tool exit failure in intermittent cutting. Journal of Harbin Institute Technology, 1997, 4(2) :107~111
32 陆剑中.金属切削原理与刀具.机械工业出版社,2004
33 Z. Klim, Cutting tool reliability analysis for variable feed milling of 17-4PH stainless steel. Wear. 1996, 195: 206~213
34 Z.J. Li, G.Y. Tan, Y.B. Wang, Y.M. Rong. A Rise in Temperature by Moving Planar Sources of Heat on the Rake Face for the Waved-edge Milling Inserts. Key Engineering Materials, 2004, 259~260: 342~346
35 P. Srinivasa Pai, T. N. Nagabuhshana, P. K. Ramakrishna Rao. Flank Wear Estimation in Face Milling Based on Radial Basis Function Neural Networks. Int. J. of Adv. Manuf. Technol., 2002, 20: 241~247
36 Barry, Byrne. Cutting tool wear in the machining of hard steels Wear, 2001, 27(6): 782~788.
37 X. D. Fang, D Zhang, An investigation of adhering layer formation during tool wear progression turning of free-cutting stainless steel Wear. 1996, 197: 169~178
38 达世亮.汽车工业切削与刀具技术现状.工具技术,2004,38(9):38~42
39 韩荣第,周明.金属切削原理与刀具.哈尔滨工业大学出版社,1998
40 孙有社,尤伦超.国内外刀具材料的发展与应用前景.机械工程师,2002,(3):10~12
41 刘孝敏.工程材料的为细观结构合力学性能.中国科学技术出版社,2003
42 李兆坤.三维复杂槽型铣刀片应力场分析及评价.哈尔滨理工大学硕士论文,2005
43 T.I.El-Wardany, E.Mohammed and M.A.Elbestawi. Cutting Temperature of Ceramic Tools in High Speed Machining of Difficult-to-Cut Materials. Journal of Manufacturing Science and Engineering. 1999, l(8): 121~501
44 王凤丽.三维复杂槽型铣刀片温度场可视化及评价准则研究.哈尔滨理工大学硕士论文,2003
45 H. Huang., Y.C. Liu. Experimental investigations of machining characteristics and removal mechanisms of advanced ceramics in high speed deep grinding. International Journal of Machine Tools & Manufacture, 2003, 43: 811~823
46 Mackawa K. Finite element analysis of behavior in metal machining. International Journal of JSME, Series C, 1996, 39(4): 864~870
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