三维槽型可转位刀片的开发研究
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摘要
本文是黑龙江省重大科技攻关项目:“大型、复杂零部件用现代刀具系列产品化与开发研究”课题中的部分研究成果的总结。可转位刀片优化其槽型可使其切削性能得到改善,多年以来人们对刀片的三维槽型进行了深入的研究,取得了很多重要的成果,但随着工业的发展不断对刀片的切削性能提出新的要求,本文对三维槽型刀片进行了较系统的实验研究、理论研究、产品开发和设计,其主要内容:
1.采用不同材质、槽型的铣刀片切削不同工件材料进行切削力对比试验研究。在不同切削参数下采用平前刀面铣刀片和三维槽型波形刃铣刀片,采用超细晶粒材质铣刀片和4030、4040切削45号钢和不锈钢进行切削力对比试验研究;并在电机厂对上述刀片进行寿命对比试验研究。
2.对重型车刀片进行二维、三维槽型的开发研究。对大型容器新产品切削加工用重型车刀片进行结构设计及槽形设计,对车刀片槽型的磨削工艺进行理论分析,并应用VC完成计算应用程序的编制,重型车刀片不同槽形槽宽、前角设计完成后应用该程序可以得到砂轮进行磨削的倾斜角。
3.对圆柱螺旋刃铣刀片的的刃型优越性进行了研究。得出圆柱螺旋刃的空间几何模型并对螺旋刃铣刀片和直刃铣刀片的加工表面波度误差进行对比分析,对圆柱螺旋刃铣刀片进行了优化设计。
4.运用I—DEAS软件中有限元分析模块对铣刀片受力情况进行有限元分析,从不同角度可以看到三维复杂槽型螺旋刃铣刀片在切削加工时的受力情况;对三维复杂槽型螺旋刃铣刀片和相同尺寸的直线刃带修光刃铣刀片以及直线刃封闭槽铣刀片有限元对比分析。
This thesis comes to the conclusions that are parts of research achievements of an important technology project,which belongs to Heilongjiang province and is“product and research of large-scale complicacy parts with modern knife series”. Milling tool optimizes its groove to make machinability better. People worked on research of 3D groove inserts for many years and got lots of important achievements. With continuously development of industries,new requirements of tool’s machinability are proposed. This paper proceed system research, theoretical research and development design of products. The main contents of this paper are following:
1. Using different material,groove inserts to cut different workpiece and contrast research of milling experiments with cutting force. The contrast research of milling experiments is proceed using different experiment’s parameters with plane milling insert, 3D groove wave milling insert,Ultra-fine grain,4030,4050. Contrast research of these tools’life is made by milling experiments in HEC.
2. Developing 2D and 3D groove of heavy cutting inserts. Structure and groove of heavy cutting insert for cutting large-scale container are designed. Theoretical analysis is made for grinding planning of tool’s groove. Calculating soft is programmed using VC. After groove width and forth angle in heavy cutting tools are completed,roll of grinding wheel will be got when applicating the program.
3. Through research of cylinder spiral milling insert , we get space geometrical model of spiral blade and proceed surface waviness error analysis of spiral and straight blade. According to cutting theory, we proceed optimum design of cylinder spiral.
1.采用不同材质、槽型的铣刀片切削不同工件材料进行切削力对比试验研究。在不同切削参数下采用平前刀面铣刀片和三维槽型波形刃铣刀片,采用超细晶粒材质铣刀片和4030、4040切削45号钢和不锈钢进行切削力对比试验研究;并在电机厂对上述刀片进行寿命对比试验研究。
2.对重型车刀片进行二维、三维槽型的开发研究。对大型容器新产品切削加工用重型车刀片进行结构设计及槽形设计,对车刀片槽型的磨削工艺进行理论分析,并应用VC完成计算应用程序的编制,重型车刀片不同槽形槽宽、前角设计完成后应用该程序可以得到砂轮进行磨削的倾斜角。
3.对圆柱螺旋刃铣刀片的的刃型优越性进行了研究。得出圆柱螺旋刃的空间几何模型并对螺旋刃铣刀片和直刃铣刀片的加工表面波度误差进行对比分析,对圆柱螺旋刃铣刀片进行了优化设计。
4.运用I—DEAS软件中有限元分析模块对铣刀片受力情况进行有限元分析,从不同角度可以看到三维复杂槽型螺旋刃铣刀片在切削加工时的受力情况;对三维复杂槽型螺旋刃铣刀片和相同尺寸的直线刃带修光刃铣刀片以及直线刃封闭槽铣刀片有限元对比分析。
This thesis comes to the conclusions that are parts of research achievements of an important technology project,which belongs to Heilongjiang province and is“product and research of large-scale complicacy parts with modern knife series”. Milling tool optimizes its groove to make machinability better. People worked on research of 3D groove inserts for many years and got lots of important achievements. With continuously development of industries,new requirements of tool’s machinability are proposed. This paper proceed system research, theoretical research and development design of products. The main contents of this paper are following:
1. Using different material,groove inserts to cut different workpiece and contrast research of milling experiments with cutting force. The contrast research of milling experiments is proceed using different experiment’s parameters with plane milling insert, 3D groove wave milling insert,Ultra-fine grain,4030,4050. Contrast research of these tools’life is made by milling experiments in HEC.
2. Developing 2D and 3D groove of heavy cutting inserts. Structure and groove of heavy cutting insert for cutting large-scale container are designed. Theoretical analysis is made for grinding planning of tool’s groove. Calculating soft is programmed using VC. After groove width and forth angle in heavy cutting tools are completed,roll of grinding wheel will be got when applicating the program.
3. Through research of cylinder spiral milling insert , we get space geometrical model of spiral blade and proceed surface waviness error analysis of spiral and straight blade. According to cutting theory, we proceed optimum design of cylinder spiral.
引文
1 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
2 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
3 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
4 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
5 TIBOR CSELLE, usw. LARC: neue, industrielle beshichtugstechonlogie. Werkstatt und Betrieb,2003,3:12~17
6 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
7 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
8 胡红兵. 1991-1995 年中国工具工业概况. 工具展望,1997,(1): 1~6
9 沈壮行. 工具工业面临的严重挑战和发展对策. 工具展望,1995,(4): 1~8
10 郑敏利.切削形成与折断过程及其预报系统.机械工业出版社,2001:29~31
11 刘献礼,陈波.磨削圆弧形断屑时砂轮倾斜角公式的推导及槽型的计算机模拟.机械工程师,1995.
12 龚智辉,宾鸿赞.螺旋角的广义定义及其应用.中国机械工程,1994
13 阎开印,周汝忠.硬质合金可转位长刃立铣刀加工表面波度误差的补偿.工具技术,2001,(35):28~29
14 林祖鑫.曲面等螺旋角刀具的设计计算与数控加工.刀具研究,1988,(4):1~18
15 赖国鹏.可转位立铣刀的形面分析和加工表面形状分析.工具技术,1990
16 高佑方.刀具的切削刃结构和立铣刀的数学模型研究.洙洲工学院学报.2001,(3):54~57
17 肖金陵,周云飞等.球头立铣刀的数控刃磨加工.工具技术,2001
18 肖诗纲.刀具材料及其合理选择.机械工业出版社,1981
19 马二恩.水花岗岩车削刀具性能初探.清华大学出版社,1995
20 李振加等. 切屑折断过程研究.机械工业出版社,1996
21 李振加等.切屑空间运动轨迹及其约束方程的研究.机械工程学报,2001,37(12):42~46
22 李振加等.波形刃铣刀片的开发及其铣削力数学模型.机械工程学报,2000,36(10):42~45
23 张智海等.铣削力、扭矩的解析卷积模型.清华大学学报,2000,(40):11~13
24 姚英学等.平头立铣刀铣削力模型中积分限的确定方法.工具技术,2004,(38):11~13
25 冯志勇等.一种新的铣削力模型.天津大学学报,1998,(31):14~19
26 张祥永等.立铣刀螺旋角大小对切削性能的影响.西北轻工业学院,1999,(17):14~19
27 张简坤正等.I-DEAS 入门.科学出版社,2000
28 刘清吉等.I-DEAS 进阶.科学出版社,2001
29 方新等.I-DEAS 产品创成式加工指南.机械工业出版社,2001
30 Edward B.Magrab.An Enginee’s Guide to MATLAB.
31 张方瑞等.UG NX 入门精解与实战技巧.电子工业出版社,1999
32 《重型切削实用技术手册》编写组.重型切削实用技术手册.机械工业出版社,1994:228～301
33 孔庆复. 计算机辅助设计与制造.哈尔滨工业大学出版社,1994:1～12
34 大连理工大学工程画教研室.机械制图.高等教育出版社,1993:59～70
35 龚智辉 宾鸿赞.螺旋角的广义定义及其应用.中国机械工程,1994:7~12
36 Beverly, A. Deckert. CAM Software Makes Its Mark. Computer Aided Engineering. 1995,46(2)
37 Karl Katbi. Modern Chip Groove. Cutting Tool Engineering, April, 1990
38 Gary Conkol Shopping for CAD/CAM. Cutting Tool Engineering. 1995,47(3):123~127
39 R. Werheim,A. Satron and A. Ber. Modifications of the Cutting Edg e Geometry and Chip Formation in Milling. Annals of the CIRP. 1994
40 The Association for Manufacturing Technology.IMTS96: What’s in the Mix for
96. Cutting Tool Engineering. 1996
41 T.Hoshi. Development of High-performance Machining Technologies. International Conference on Machining Technology in Asian & Pacific Regions. Guangzhou,1993
42 博弈创作室.ANSYS7.0 基础教程与实例详解.中国水利水电出版社,2004
43 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
44 杨广勇,杨育民.金属切削原理与刀具.北京理工大学出版社,1994
45 海市金属切削技术协会.金属切削手册.上海科学技术出版社,1984
46 中山一雄.金属切削加工理论.李云芳.机械工业出版社,1985
47 沈维道,郑佩芝,蒋淡安.工程热力学.高等教育出版社,1983
48 Lin J. Inverse estimation the tool-work interface temperature in end milling. Int. J. Mach. Tools Manufact., 1995:58~61
49 Hamid A. A. A three dimensional finite element thermo-mechanical analysis of intermittent cutting process. Journal of Materials Processing Technology, 1996:12~23
50 Mackawa K. Finite element analysis of behavior in metal machining. International Journal of JSME, Series C, 1996, 39(4): 864~870
51 M.K.Alam, R.L.Goetz, S.L.Semiain. Modeling of Thermal Stresses and Thermal Cracking During Heating of Large Lngots. Journal of Manufacturing Science and Engineering, 1999:521~525
2 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
3 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
4 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
5 TIBOR CSELLE, usw. LARC: neue, industrielle beshichtugstechonlogie. Werkstatt und Betrieb,2003,3:12~17
6 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
7 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
8 胡红兵. 1991-1995 年中国工具工业概况. 工具展望,1997,(1): 1~6
9 沈壮行. 工具工业面临的严重挑战和发展对策. 工具展望,1995,(4): 1~8
10 郑敏利.切削形成与折断过程及其预报系统.机械工业出版社,2001:29~31
11 刘献礼,陈波.磨削圆弧形断屑时砂轮倾斜角公式的推导及槽型的计算机模拟.机械工程师,1995.
12 龚智辉,宾鸿赞.螺旋角的广义定义及其应用.中国机械工程,1994
13 阎开印,周汝忠.硬质合金可转位长刃立铣刀加工表面波度误差的补偿.工具技术,2001,(35):28~29
14 林祖鑫.曲面等螺旋角刀具的设计计算与数控加工.刀具研究,1988,(4):1~18
15 赖国鹏.可转位立铣刀的形面分析和加工表面形状分析.工具技术,1990
16 高佑方.刀具的切削刃结构和立铣刀的数学模型研究.洙洲工学院学报.2001,(3):54~57
17 肖金陵,周云飞等.球头立铣刀的数控刃磨加工.工具技术,2001
18 肖诗纲.刀具材料及其合理选择.机械工业出版社,1981
19 马二恩.水花岗岩车削刀具性能初探.清华大学出版社,1995
20 李振加等. 切屑折断过程研究.机械工业出版社,1996
21 李振加等.切屑空间运动轨迹及其约束方程的研究.机械工程学报,2001,37(12):42~46
22 李振加等.波形刃铣刀片的开发及其铣削力数学模型.机械工程学报,2000,36(10):42~45
23 张智海等.铣削力、扭矩的解析卷积模型.清华大学学报,2000,(40):11~13
24 姚英学等.平头立铣刀铣削力模型中积分限的确定方法.工具技术,2004,(38):11~13
25 冯志勇等.一种新的铣削力模型.天津大学学报,1998,(31):14~19
26 张祥永等.立铣刀螺旋角大小对切削性能的影响.西北轻工业学院,1999,(17):14~19
27 张简坤正等.I-DEAS 入门.科学出版社,2000
28 刘清吉等.I-DEAS 进阶.科学出版社,2001
29 方新等.I-DEAS 产品创成式加工指南.机械工业出版社,2001
30 Edward B.Magrab.An Enginee’s Guide to MATLAB.
31 张方瑞等.UG NX 入门精解与实战技巧.电子工业出版社,1999
32 《重型切削实用技术手册》编写组.重型切削实用技术手册.机械工业出版社,1994:228～301
33 孔庆复. 计算机辅助设计与制造.哈尔滨工业大学出版社,1994:1～12
34 大连理工大学工程画教研室.机械制图.高等教育出版社,1993:59～70
35 龚智辉 宾鸿赞.螺旋角的广义定义及其应用.中国机械工程,1994:7~12
36 Beverly, A. Deckert. CAM Software Makes Its Mark. Computer Aided Engineering. 1995,46(2)
37 Karl Katbi. Modern Chip Groove. Cutting Tool Engineering, April, 1990
38 Gary Conkol Shopping for CAD/CAM. Cutting Tool Engineering. 1995,47(3):123~127
39 R. Werheim,A. Satron and A. Ber. Modifications of the Cutting Edg e Geometry and Chip Formation in Milling. Annals of the CIRP. 1994
40 The Association for Manufacturing Technology.IMTS96: What’s in the Mix for
96. Cutting Tool Engineering. 1996
41 T.Hoshi. Development of High-performance Machining Technologies. International Conference on Machining Technology in Asian & Pacific Regions. Guangzhou,1993
42 博弈创作室.ANSYS7.0 基础教程与实例详解.中国水利水电出版社,2004
43 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
44 杨广勇,杨育民.金属切削原理与刀具.北京理工大学出版社,1994
45 海市金属切削技术协会.金属切削手册.上海科学技术出版社,1984
46 中山一雄.金属切削加工理论.李云芳.机械工业出版社,1985
47 沈维道,郑佩芝,蒋淡安.工程热力学.高等教育出版社,1983
48 Lin J. Inverse estimation the tool-work interface temperature in end milling. Int. J. Mach. Tools Manufact., 1995:58~61
49 Hamid A. A. A three dimensional finite element thermo-mechanical analysis of intermittent cutting process. Journal of Materials Processing Technology, 1996:12~23
50 Mackawa K. Finite element analysis of behavior in metal machining. International Journal of JSME, Series C, 1996, 39(4): 864~870
51 M.K.Alam, R.L.Goetz, S.L.Semiain. Modeling of Thermal Stresses and Thermal Cracking During Heating of Large Lngots. Journal of Manufacturing Science and Engineering, 1999:521~525
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