高速铣削铝合金切削温度的研究
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摘要
高速切削机理的研究作为高速切削技术的理论基础，是高速切削技术应用和发展的基石。在高速切削机理研究中，切削温度的研究是至关重要的，高速切削温度的分布及其变化规律是高速铣削工艺分析的主要依据之一。铝合金的高速铣削是高速切削技术的一个重要应用领域，本文对高速铣削铝合金的切削温度进行了研究。采用夹丝半人工热电偶法测量铣削区温度，对铣削温度随切削参数的变化规律进行了实验研究；针对高速铣削的加工特点，用热源法建立了高速铣削加工条件下工件温度场的理论解析模型；采用有限元分析软件ANSYS对工件的切削温度场进行了有限元仿真分析；理论解析结果和有限元仿真结果与实验结果相比较，均具有良好的一致性。
As the theory foundation of the high-speed cutting (HSC), the research of the mechanism of HSC is the foundation of the application and development of the HSC technology. In the research of the mechanism of the HSC, the cutting temperature is very important, the distribution and the change rule of the cutting temperature is one of the mostly gist of the techniques analysis in HSC. The high-speed milling (HSM) of aluminum-alloys is one of the important applied fields of the HSM technology, this paper does some research work of the cutting temperature of the HSM of aluminum-alloys. By use semi-artificial thermocouple method which nipping metal thread in work piece to measure its temperature, did some experimental researches of the change rule of the cutting temperature which following the cutting parameter; In allusion to the machining characteristic of the HSM, established theoretical model of the work piece temperature field by using the method of heat source; Used the software ANSYS to carry out the finite
element simulation analysis of the cutting temperature field of the work piece; The comparison of the results of the theoretical model and the finite element simulation and the data of the experiment showed that they had good concordance.
As the theory foundation of the high-speed cutting (HSC), the research of the mechanism of HSC is the foundation of the application and development of the HSC technology. In the research of the mechanism of the HSC, the cutting temperature is very important, the distribution and the change rule of the cutting temperature is one of the mostly gist of the techniques analysis in HSC. The high-speed milling (HSM) of aluminum-alloys is one of the important applied fields of the HSM technology, this paper does some research work of the cutting temperature of the HSM of aluminum-alloys. By use semi-artificial thermocouple method which nipping metal thread in work piece to measure its temperature, did some experimental researches of the change rule of the cutting temperature which following the cutting parameter; In allusion to the machining characteristic of the HSM, established theoretical model of the work piece temperature field by using the method of heat source; Used the software ANSYS to carry out the finite
element simulation analysis of the cutting temperature field of the work piece; The comparison of the results of the theoretical model and the finite element simulation and the data of the experiment showed that they had good concordance.
引文
1．张伯霖．高速切削技术及应用．北京：机械工业出版社．2002，8
2．小野浩二．理论切削学．国防工业出版社．1979
3. Salomn C. Process for the Machining of Metal or Similarly Acting Materials when being Worked by Cutting Tools. German Patent. 523594, 1931-04
4. F. Jack. McGee. STUDY: Methods for aluminium workpieces. American Machinist. 1979 (March): 121-126
5. Takashi Ueda, Mahfudz Al Huda, Keiji Yamada, Kazuo Nakayama. Temperature Measurement of CBN Tool in Turning of High Hardness Steel. Annals of the CIRP. 1999, Vol. 48/1:63-66
6．杨巧凤，张明贤，史兴宽．铝合金高速铣削温度变化规律的试验研究．西北工业大学学报．1999，17 (3)：439-443
7．陈明等．三维有限元分析在高速铣削温度研究中应用．机械工程学报．2002，7，Vol．38：76-79
8．苌浩．高速铣削加工中铣削温度的研究．南京航天航空大学硕士学位论文．2003，3
9．袁哲俊．金属切削试验技术．机械工业出版社．1988年
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12．张伯霖，谢影明，肖曙红．超高速切削的原理与应用．中国机械工程．1995年第6卷第1期
13．史兴宽，杨巧凤，张明贤．钛合金TC4高速铣削表面的温度场研究．航空制造技术．2002，1
14．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年第36卷N3
15．苗恩铭，费业泰．车刀前刀面温度的计算及参数调整．工具技术．2002年第36卷N2
16．刘德福，于晓霞，娄平宜．正交金属切削温度场有限元分析．北京理工大学学报．1999，Vol．8，No．4
17．武凯，何宁，姜澄宇等．有限元技术在航空薄壁件立铣变形分析中的应用．应用科学学报．第21卷第1期，2003年3月
18．刘有荣，刘家浚，朱宝亮．陶瓷刀具切削区温度场的计算机模拟．摩擦学学报．第17卷第1期，1997年3月
19．黄丹，刘成文，郭乙木．金属正交切削加工过程的有限元分析．机械强度．2003，25 (3)：294—297
20．方刚，曾攀．金属正交切削工艺的有限元模拟．机械科学与技术．第22卷第4期，2003年7月
21．武文革，常兴．半人工热电偶法瞬态铣削温度测量的实现．山西机械，第4期 (总第109期)．2000年12月
22．黄志刚，柯映林，王立涛．金属切削加工有限元模拟的相关技术研究．中国机械工程第14卷第10期 2003年5月下半月
23．赵吉文．二维金属切削过程计算机仿真及刀具几何参数优化．合肥工业大学硕士学位论文．2002年3月
24．许香谷，肖诗纲．金属切削原理与刀具．重庆大学出版社．1992，10
25．张幼桢．金属切削理论．航空工业出版社．1988，6
26．汪大年．金属塑性成形理论．北京：机械工业出版社．1982
27．王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社．2000，4
28．侯镇冰，何绍杰，李恕先．固体热传导．上海：上海科学技术出版社．1984
29．工程材料实用手册，V3，中国标准出版社．1989
30．刘涛，杨凤鹏．精通 ANSYS．清华大学出版社．2003
31. Jehnming Lin, Shinn-Liang Lee, Cheng Weng. Ring Materials and Technology. JULY, 1992, Vol. 114:289-296
32．康戈文，刘飞，徐宗俊，童庆明．直角干切削动态传热模型．重庆大学学报 (自然科学版)．1997年1月第20卷第1期
33. J. Q. Xie, A. E. Bayoumi, H. M. Zbib. FEA modeling and simulation of shear localized chip formation in metal cutting. International Journal of Machine Tools & Manufacture. 38 (1998): 1067-1087
34. C. R. Liu. Y. B. Guo, Finite element analysis of the elect of sequential cuts and tool-chip friction on residual stresses in a machined layer. International Journal of Mechanical Sciences. 42 (2000): 1069-1086
35. M. V. Ramesh, K. N. Seetharamu, N. Ganesan, G. Kuppuswamy. Finite element modeling of heat transfer analysis in machining of isotropie materials. International Journal of Heat and Mass Transfer. 42 (1999): 1569-1583
36. A. G. Mamalis, M. Horvath, A. S. Branis, D. E. Manolakos. Finite element
simulation of chip formation in orthogonal metal cutting. Journal of Materials Processing Technology. 110 (2001): 19-27
37. Balkrishna Rao, Yung C.Shin, Analysis in high-speed face-milling of 7075-T6 aluminium using carbide and diamond cutters. International Journal of Machine Tools&Manufacture. 2001 (41): 1763-1781
38. S. W. Kim, C. M. Lee, D. W. Lee, J. S. Kim, Y. H. Jung, Evaluation of the thermal characteristics in high-speed ball-end milling. Journal of Materials Processing Technology, 2001 (113): 406-409
39. L. Li, N. He, M. Wang, Z. G.. Wang, High speed cutting of Inconel 718 with coated carbide and ceramic inserts. Journal of Materials Processing Technology 2002. Vol. 129: 127-130
40．梁锡昌．实现超高速铣削途径的探讨．机械工艺师．2001 (1)：9-10
41．赵威，何宁，李亮，武凯．薄壁结构的高效铣削加工．航空精密制造技术．2002，12，Vol．38：12-15
42．晓立．高速加工技术的进展及应用．航空制造技术．2002 (4)：47-48
43．李亮，何宁，何磊，王珉．高速铣削铝合金时切削力和表面质量影响因素的试验研究．工具技术．2002，Vol．36：16-19
44．刘战强，艾兴．高速切削刀具磨损表面形态研究．摩擦学报．Nov，2002，Vol．22，468-471
45．刘战强．高速铣削过程中表面粗糙度变化规律的试验研究．现代制造工程．2002 (3)：8-10
46．杨广勇．超高速切削时的 T—v 关系与切削力．北京理工大学学报．1996 (6)：263-266
47．梁锡昌，郑小光，徐国斌．超高速铣削的理论研究．机械工程学报．2001 (3)，Vol．37：109-112
48. T. L. Schmitz, M. A. Davies, K. Medicus, J. Snyder. Improving High-Speed Machining Material Removal Rates by Rapid Dynamic Analysis. Annals of the CIRP. 2001, Vol. 50/1:263-268
49. T. Aoyama, I.Inasaki, Performances of riSK Tool Interfaces under High Rotation Speed, Annals of the CIRP. 2001, Vol. 50/1:281-284
50. Knut Sorby, Kjell Tonnessen, Jan Erik Torjusen, Improving High Speed Flank Milling Operations in Multi-Axis Machines, Annals of the CIRP. 2000, Vol. 49/1: 371-374
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68．张雷，高速铣削机理研究．南京理工大学硕士学位论文．2003
2．小野浩二．理论切削学．国防工业出版社．1979
3. Salomn C. Process for the Machining of Metal or Similarly Acting Materials when being Worked by Cutting Tools. German Patent. 523594, 1931-04
4. F. Jack. McGee. STUDY: Methods for aluminium workpieces. American Machinist. 1979 (March): 121-126
5. Takashi Ueda, Mahfudz Al Huda, Keiji Yamada, Kazuo Nakayama. Temperature Measurement of CBN Tool in Turning of High Hardness Steel. Annals of the CIRP. 1999, Vol. 48/1:63-66
6．杨巧凤，张明贤，史兴宽．铝合金高速铣削温度变化规律的试验研究．西北工业大学学报．1999，17 (3)：439-443
7．陈明等．三维有限元分析在高速铣削温度研究中应用．机械工程学报．2002，7，Vol．38：76-79
8．苌浩．高速铣削加工中铣削温度的研究．南京航天航空大学硕士学位论文．2003，3
9．袁哲俊．金属切削试验技术．机械工业出版社．1988年
10．中山一雄．金属切削加工理论．机械工业出版社．1985，3
11．周忆，梁锡昌．超高速铣削加工的温度场计算及生产应用．中国机械工程第 14卷第13期，2003，7
12．张伯霖，谢影明，肖曙红．超高速切削的原理与应用．中国机械工程．1995年第6卷第1期
13．史兴宽，杨巧凤，张明贤．钛合金TC4高速铣削表面的温度场研究．航空制造技术．2002，1
14．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年第36卷N3
15．苗恩铭，费业泰．车刀前刀面温度的计算及参数调整．工具技术．2002年第36卷N2
16．刘德福，于晓霞，娄平宜．正交金属切削温度场有限元分析．北京理工大学学报．1999，Vol．8，No．4
17．武凯，何宁，姜澄宇等．有限元技术在航空薄壁件立铣变形分析中的应用．应用科学学报．第21卷第1期，2003年3月
18．刘有荣，刘家浚，朱宝亮．陶瓷刀具切削区温度场的计算机模拟．摩擦学学报．第17卷第1期，1997年3月
19．黄丹，刘成文，郭乙木．金属正交切削加工过程的有限元分析．机械强度．2003，25 (3)：294—297
20．方刚，曾攀．金属正交切削工艺的有限元模拟．机械科学与技术．第22卷第4期，2003年7月
21．武文革，常兴．半人工热电偶法瞬态铣削温度测量的实现．山西机械，第4期 (总第109期)．2000年12月
22．黄志刚，柯映林，王立涛．金属切削加工有限元模拟的相关技术研究．中国机械工程第14卷第10期 2003年5月下半月
23．赵吉文．二维金属切削过程计算机仿真及刀具几何参数优化．合肥工业大学硕士学位论文．2002年3月
24．许香谷，肖诗纲．金属切削原理与刀具．重庆大学出版社．1992，10
25．张幼桢．金属切削理论．航空工业出版社．1988，6
26．汪大年．金属塑性成形理论．北京：机械工业出版社．1982
27．王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社．2000，4
28．侯镇冰，何绍杰，李恕先．固体热传导．上海：上海科学技术出版社．1984
29．工程材料实用手册，V3，中国标准出版社．1989
30．刘涛，杨凤鹏．精通 ANSYS．清华大学出版社．2003
31. Jehnming Lin, Shinn-Liang Lee, Cheng Weng. Ring Materials and Technology. JULY, 1992, Vol. 114:289-296
32．康戈文，刘飞，徐宗俊，童庆明．直角干切削动态传热模型．重庆大学学报 (自然科学版)．1997年1月第20卷第1期
33. J. Q. Xie, A. E. Bayoumi, H. M. Zbib. FEA modeling and simulation of shear localized chip formation in metal cutting. International Journal of Machine Tools & Manufacture. 38 (1998): 1067-1087
34. C. R. Liu. Y. B. Guo, Finite element analysis of the elect of sequential cuts and tool-chip friction on residual stresses in a machined layer. International Journal of Mechanical Sciences. 42 (2000): 1069-1086
35. M. V. Ramesh, K. N. Seetharamu, N. Ganesan, G. Kuppuswamy. Finite element modeling of heat transfer analysis in machining of isotropie materials. International Journal of Heat and Mass Transfer. 42 (1999): 1569-1583
36. A. G. Mamalis, M. Horvath, A. S. Branis, D. E. Manolakos. Finite element
simulation of chip formation in orthogonal metal cutting. Journal of Materials Processing Technology. 110 (2001): 19-27
37. Balkrishna Rao, Yung C.Shin, Analysis in high-speed face-milling of 7075-T6 aluminium using carbide and diamond cutters. International Journal of Machine Tools&Manufacture. 2001 (41): 1763-1781
38. S. W. Kim, C. M. Lee, D. W. Lee, J. S. Kim, Y. H. Jung, Evaluation of the thermal characteristics in high-speed ball-end milling. Journal of Materials Processing Technology, 2001 (113): 406-409
39. L. Li, N. He, M. Wang, Z. G.. Wang, High speed cutting of Inconel 718 with coated carbide and ceramic inserts. Journal of Materials Processing Technology 2002. Vol. 129: 127-130
40．梁锡昌．实现超高速铣削途径的探讨．机械工艺师．2001 (1)：9-10
41．赵威，何宁，李亮，武凯．薄壁结构的高效铣削加工．航空精密制造技术．2002，12，Vol．38：12-15
42．晓立．高速加工技术的进展及应用．航空制造技术．2002 (4)：47-48
43．李亮，何宁，何磊，王珉．高速铣削铝合金时切削力和表面质量影响因素的试验研究．工具技术．2002，Vol．36：16-19
44．刘战强，艾兴．高速切削刀具磨损表面形态研究．摩擦学报．Nov，2002，Vol．22，468-471
45．刘战强．高速铣削过程中表面粗糙度变化规律的试验研究．现代制造工程．2002 (3)：8-10
46．杨广勇．超高速切削时的 T—v 关系与切削力．北京理工大学学报．1996 (6)：263-266
47．梁锡昌，郑小光，徐国斌．超高速铣削的理论研究．机械工程学报．2001 (3)，Vol．37：109-112
48. T. L. Schmitz, M. A. Davies, K. Medicus, J. Snyder. Improving High-Speed Machining Material Removal Rates by Rapid Dynamic Analysis. Annals of the CIRP. 2001, Vol. 50/1:263-268
49. T. Aoyama, I.Inasaki, Performances of riSK Tool Interfaces under High Rotation Speed, Annals of the CIRP. 2001, Vol. 50/1:281-284
50. Knut Sorby, Kjell Tonnessen, Jan Erik Torjusen, Improving High Speed Flank Milling Operations in Multi-Axis Machines, Annals of the CIRP. 2000, Vol. 49/1: 371-374
51. Marcel Gaxotte. High-speed machining requires concentrated effort from users who
wish to achieve optimum results. Manufacturing Engineering. 2001 (3): 106-113
52. Matthew A. Davies, Tony L. Schmitz, Brian. S. Dutterer, How to Succeed at HSM. Manufacturing Engineering. 2001 (3): 90-104
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