不锈钢加工中切削力分析预测研究
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摘要
金属切削是制造领域的基础工艺。随着工件材料性能的不断提升以及零件在特殊环境(高温，高压，强辐照，强腐蚀)下服役性能的要求越来越高，对零件加工质量提出了更高的要求。本文以核主泵难加工材料为主要研究对象，综合考虑金属切削过程中材料性能、非线性大变形特性、热力耦合等因素的影响，对金属切削过程的直角切削和斜角切削等几个基本问题进行了研究，实现了304不锈钢加工过程中切削力的预测。其主要研究工作和成果如下：
首先分析了主剪切区的模型化方法，提出了不等分剪切区模型。在剪切区，用Johnson-Cook方程表示材料的本构关系。假设切屑形成主要是由剪切滑移作用的结果，切削刃钝圆半径的影响被忽略。根据Oxley实验结果，把剪切区应变率分布表示为幂律分布曲线。基于塑性力学和热力学原理，建立了切屑通过剪切区的速度、应变、应力和温度的控制方程。在刀屑面上，引入了依赖切屑速度的摩擦经验公式。通过数值方法对强耦合条件下的热力控制方程组进行同时求解，在计算流动应力时考虑了加工硬化和热软化的影响。最后预测了各种不同加工条件下的切削力，讨论了不同切削参数对切削力的影响。同时也分析了剪切区的应变率，速度，应变，温度和应力变化规律。
通过定义等效平面角来确定等效平面的方位，并应用等效平面法把直角切削理论延伸到斜角切削的建模。用坐标变化法研究斜角切削中的几何关系，分析了斜角切削中的速度变化过程。与直角切削类似，建立了切屑通过剪切区的速度、应变、应力和温度的控制方程。推导了斜角切削中切屑受力的关系，通过切屑的受力平衡，得到切屑流角和切削力表达式。对斜角切削的控制方程进行数值求解，可以得到不同切削参数和刃倾角对切削力的影响规律。
分析了立铣刀的切削刃离散过程，定义局部切削角度和未变形切屑厚度来确定离散刃的切削参数。把每个离散刃看做一系列的斜角切削单元，对每个微元斜角切削单元，由材料本构方程、剪切区热力控制方程、剪切角公式和平均摩擦角公式等预测出流动应力，然后计算出微元切削力。根据斜角切削和铣削之间的力变换关系，把微元切削力转化为微元铣削力。对微元铣削力进行数值积分求和，得到铣削力的大小。根据本文提出方法，分析了刀具参数和切削参数对铣削力的影响规律。分析结果表明可以通过选择合适的刀具参数和铣削参数得到一个理想的铣削力分布(满足连续性，平稳性，和最小性条件)，从而减小刀具变形误差和提高加工精度。这对基于切削力的工艺参数优化和刀具路线规划奠定了基础。
讨论了传统斜角切削模型的局限性，提出了一个改进的斜角切削模型，它考虑了主偏角影响和非自由切削作用。运用坐标变换法分析了车削中离散切削刃的几何关系，推导了局部切削角度和局部切削参数的数学表达式。把每个离散切削刃看作一个改进斜角切削过程，考虑了切屑单元之间的相互作用。根据每个离散切屑单元的局部受力平衡和整个切屑的全局受力平衡，得到全局切屑流角和车削力的表达关系式。通过数值方法，对车削过程进行求解。应用提出模型对三种情况下的车削力进行预测分析，特别是刀尖圆弧半径和主偏角等非自由因素对车削力的影响。研究了车削中的切屑流出方向，分析了刀具参数和切削参数对局部和全局切屑流角的影响。结果表明可以通过选择合适的刃倾角、主偏角、刀尖圆弧半径和切削深度来控制切屑流出方向，使其往工件轴向外面偏，避免刮伤已加工表面。最后对车削过程的局部几何参数和物理参数进行分析，各种影响包括刀具角度和切削参数被看做是一个耦合作用。这些局部信息对于优化切削参数和切削刃的形状具有重要意义。
在Matlab平台上开发基于本文提出方法软件包，并通过一系列的直角切削实验来识别材料常数和摩擦常数。将预测结果与304不锈钢切削力实验进行对比，验证本文提出模型的有效性，初步建立了核主泵常见加工工序(铣削和车削)的切削力数学模型。为了进一步考察本文提出方法的广泛性，也与其它金属材料的实验结果进行了比较，如42CrMo4钢与316L不锈钢的文献结果，45钢铣削实验。本文提出的模型也可用于其它切削加工方法的建模，如钻削和镗削。
Metal cutting is the most traditional material processing technology in mechanicalmanufacturing industry. As the material property improvment and some special serviceenvironment demand (high termperature， high pressure， irradiation， corrosion), themanchining quality need be more strictly controled. This dissertation focuses on cutting forceprediction for the difficult-cut-materials (304stainless steel) of nuclear reactor coolant pump,some principle problems about orthogonal cutting and oblique cutting are researched. Thematerial property, nolinear large deformation and thermomechanical coupling of cuttingprocesss are also considered together. These work and achievements are shown below:
First of all, the modeling process of the primary shear zone is discussed. A new modelbased on unequally divided shear zone is presented. The material constitutive relationship inthe primary shear zone is represented using Johnson-Cook equation. The chip formation issupposed to occur mainly by shearing within a primary shear zone, and the tool edge radiuseffects can be neglected under the assumption of a sharp cutting edge. A piecewise power lawdistribution assumption of the shear strain rate is adopted according to Oxley’s experimentalresualts. Based on plastic mechanics and thermodynamics, the governing equations of thevelocity, strain, stress and temperature of chip flow through the primary shear zone areestablished. At the tool/chip interface, a chip speed-dependent friction law is introduced.While calculating the flow stress numerically, the thermomechanical equations under thestrong coupling condition are solved simultaneously, so the coupling effect of workinghardening and thermal softening on flow stress are considered. Finally, the cutting forces fordifferent machining conditions were predicted, the effect of cutting parameters and toolgeometry were investigated. Besides, the distributions of strain rate, velocity, strain, stressand temperature for the proposed model are also simulated.
Using the equivalent plane approach, orthogonal cutting theory based on unequaldivision shear zone is extended and applied to oblique cutting. The equivalent plane angle is defined to determine the orientation of the equivalent plane. The geometrical parametersassociated to oblique cutting are analyzed using the coordinate transformation approach.Similarly, the governing equations of the shear velocity, shear strain, shear stress andtemperature distribution in the primary shear zone are established. The forces applied on chipare analysed, the calculated expression of cutting forces and chip flow angle are deduced onthe basis of chip force equilibrium. The cutting force prediction process of oblique machiningis implemented using a program, the influence of cutting parameters and inclination anglewere investigated.
The helical flutes are decomposed into a set of differential oblique cutting edges. Thecutting parameters of discrete edges are characterized by local cutting angle and theundeformed chip thickness. To every engaged tooth element, the flow stress is obtained fromthe material constitutive equation, the thermomechanical governing equations within theprimary shear zone, the shear angle formula, the mean friction expression at the tool-chipinterface and so on, then differential cutting forces are computed by the flow stress. Cuttingforces were predicted using oblique cutting transformation into end milling. The value of themilling force is calculated through the numerical integration. Using the proposed method, theeffect of tool and cutting parameters on milling force are analysed. The results show that it’spossible to get an ideal milling force distribution (To meet the continuity, stability, andminimum conditions) by choosing the appropriate machining parameter, which can reducetool deflection error and improve the maching precision. This work is the foundation ofmachining parameter optimization and toolpath planning based on cutting force.
This dissertation discusses the limitations of the traditional oblique cutting model andproposes a more general oblique cutting model. The improved model considers the impact ofmain cutting edge angle and non-free cutting. Based on the coordinate transformations, weanalyse the geometry relationships of discrete cutting edges and deduce the mathematicalexpressions of the local cutting angles and cutting parameters. Every discrete cutting elementcan be considered as an improved oblique cutting process, which takes into account theinteraction between the chip elements. The relationship of the global chip flow angle and the turning force can be derived based on force equilibrium of each local chip element and theglobal chip. The proposed model has been applied to predict and analyse the turning force inthe three distinct cases, especially in the case of non-free factors of the corner radius and maincutting edge angle. The chip flow in turning may scratch the machined surface, under thecircumstances, the surface will have a poor quality. We investigated the influence of the tooland cutting parameters on the local and global chip flow angle. The results helpmanufacturing engineers to choose the cutting angle, nose radius and cutting depth to controlchip flow direction towards the outside of the workpiece axis. Finally, the tool and cuttingparameter effect on the local geometric and physical parameters along the cutting edge areconsidered as coupled. These local information is important to the optimization of cuttingparameters and the cutting edge geometry.
The proposed method in this dissertation has been implemented in Matlab7.0. Based on aset of orthogonal cutting tests, the material and friction coefficients are indentified. Predictedresults were compared with experiment results of cutting forces for304stainless steel andfound in reasonable agreement. So this model can be used to analyse the cutting process of thenuclear reactor coolant pump. This model is also validated by the experimental results ofother materials, such as literature results of42CrMo4steel and316L stainless steel, millingexperimental results of45steel. It should be noted that although this work is limited tomilling and turning, the present method also be applied to other machining operations such asdrilling and boring.
首先分析了主剪切区的模型化方法，提出了不等分剪切区模型。在剪切区，用Johnson-Cook方程表示材料的本构关系。假设切屑形成主要是由剪切滑移作用的结果，切削刃钝圆半径的影响被忽略。根据Oxley实验结果，把剪切区应变率分布表示为幂律分布曲线。基于塑性力学和热力学原理，建立了切屑通过剪切区的速度、应变、应力和温度的控制方程。在刀屑面上，引入了依赖切屑速度的摩擦经验公式。通过数值方法对强耦合条件下的热力控制方程组进行同时求解，在计算流动应力时考虑了加工硬化和热软化的影响。最后预测了各种不同加工条件下的切削力，讨论了不同切削参数对切削力的影响。同时也分析了剪切区的应变率，速度，应变，温度和应力变化规律。
通过定义等效平面角来确定等效平面的方位，并应用等效平面法把直角切削理论延伸到斜角切削的建模。用坐标变化法研究斜角切削中的几何关系，分析了斜角切削中的速度变化过程。与直角切削类似，建立了切屑通过剪切区的速度、应变、应力和温度的控制方程。推导了斜角切削中切屑受力的关系，通过切屑的受力平衡，得到切屑流角和切削力表达式。对斜角切削的控制方程进行数值求解，可以得到不同切削参数和刃倾角对切削力的影响规律。
分析了立铣刀的切削刃离散过程，定义局部切削角度和未变形切屑厚度来确定离散刃的切削参数。把每个离散刃看做一系列的斜角切削单元，对每个微元斜角切削单元，由材料本构方程、剪切区热力控制方程、剪切角公式和平均摩擦角公式等预测出流动应力，然后计算出微元切削力。根据斜角切削和铣削之间的力变换关系，把微元切削力转化为微元铣削力。对微元铣削力进行数值积分求和，得到铣削力的大小。根据本文提出方法，分析了刀具参数和切削参数对铣削力的影响规律。分析结果表明可以通过选择合适的刀具参数和铣削参数得到一个理想的铣削力分布(满足连续性，平稳性，和最小性条件)，从而减小刀具变形误差和提高加工精度。这对基于切削力的工艺参数优化和刀具路线规划奠定了基础。
讨论了传统斜角切削模型的局限性，提出了一个改进的斜角切削模型，它考虑了主偏角影响和非自由切削作用。运用坐标变换法分析了车削中离散切削刃的几何关系，推导了局部切削角度和局部切削参数的数学表达式。把每个离散切削刃看作一个改进斜角切削过程，考虑了切屑单元之间的相互作用。根据每个离散切屑单元的局部受力平衡和整个切屑的全局受力平衡，得到全局切屑流角和车削力的表达关系式。通过数值方法，对车削过程进行求解。应用提出模型对三种情况下的车削力进行预测分析，特别是刀尖圆弧半径和主偏角等非自由因素对车削力的影响。研究了车削中的切屑流出方向，分析了刀具参数和切削参数对局部和全局切屑流角的影响。结果表明可以通过选择合适的刃倾角、主偏角、刀尖圆弧半径和切削深度来控制切屑流出方向，使其往工件轴向外面偏，避免刮伤已加工表面。最后对车削过程的局部几何参数和物理参数进行分析，各种影响包括刀具角度和切削参数被看做是一个耦合作用。这些局部信息对于优化切削参数和切削刃的形状具有重要意义。
在Matlab平台上开发基于本文提出方法软件包，并通过一系列的直角切削实验来识别材料常数和摩擦常数。将预测结果与304不锈钢切削力实验进行对比，验证本文提出模型的有效性，初步建立了核主泵常见加工工序(铣削和车削)的切削力数学模型。为了进一步考察本文提出方法的广泛性，也与其它金属材料的实验结果进行了比较，如42CrMo4钢与316L不锈钢的文献结果，45钢铣削实验。本文提出的模型也可用于其它切削加工方法的建模，如钻削和镗削。
Metal cutting is the most traditional material processing technology in mechanicalmanufacturing industry. As the material property improvment and some special serviceenvironment demand (high termperature， high pressure， irradiation， corrosion), themanchining quality need be more strictly controled. This dissertation focuses on cutting forceprediction for the difficult-cut-materials (304stainless steel) of nuclear reactor coolant pump,some principle problems about orthogonal cutting and oblique cutting are researched. Thematerial property, nolinear large deformation and thermomechanical coupling of cuttingprocesss are also considered together. These work and achievements are shown below:
First of all, the modeling process of the primary shear zone is discussed. A new modelbased on unequally divided shear zone is presented. The material constitutive relationship inthe primary shear zone is represented using Johnson-Cook equation. The chip formation issupposed to occur mainly by shearing within a primary shear zone, and the tool edge radiuseffects can be neglected under the assumption of a sharp cutting edge. A piecewise power lawdistribution assumption of the shear strain rate is adopted according to Oxley’s experimentalresualts. Based on plastic mechanics and thermodynamics, the governing equations of thevelocity, strain, stress and temperature of chip flow through the primary shear zone areestablished. At the tool/chip interface, a chip speed-dependent friction law is introduced.While calculating the flow stress numerically, the thermomechanical equations under thestrong coupling condition are solved simultaneously, so the coupling effect of workinghardening and thermal softening on flow stress are considered. Finally, the cutting forces fordifferent machining conditions were predicted, the effect of cutting parameters and toolgeometry were investigated. Besides, the distributions of strain rate, velocity, strain, stressand temperature for the proposed model are also simulated.
Using the equivalent plane approach, orthogonal cutting theory based on unequaldivision shear zone is extended and applied to oblique cutting. The equivalent plane angle is defined to determine the orientation of the equivalent plane. The geometrical parametersassociated to oblique cutting are analyzed using the coordinate transformation approach.Similarly, the governing equations of the shear velocity, shear strain, shear stress andtemperature distribution in the primary shear zone are established. The forces applied on chipare analysed, the calculated expression of cutting forces and chip flow angle are deduced onthe basis of chip force equilibrium. The cutting force prediction process of oblique machiningis implemented using a program, the influence of cutting parameters and inclination anglewere investigated.
The helical flutes are decomposed into a set of differential oblique cutting edges. Thecutting parameters of discrete edges are characterized by local cutting angle and theundeformed chip thickness. To every engaged tooth element, the flow stress is obtained fromthe material constitutive equation, the thermomechanical governing equations within theprimary shear zone, the shear angle formula, the mean friction expression at the tool-chipinterface and so on, then differential cutting forces are computed by the flow stress. Cuttingforces were predicted using oblique cutting transformation into end milling. The value of themilling force is calculated through the numerical integration. Using the proposed method, theeffect of tool and cutting parameters on milling force are analysed. The results show that it’spossible to get an ideal milling force distribution (To meet the continuity, stability, andminimum conditions) by choosing the appropriate machining parameter, which can reducetool deflection error and improve the maching precision. This work is the foundation ofmachining parameter optimization and toolpath planning based on cutting force.
This dissertation discusses the limitations of the traditional oblique cutting model andproposes a more general oblique cutting model. The improved model considers the impact ofmain cutting edge angle and non-free cutting. Based on the coordinate transformations, weanalyse the geometry relationships of discrete cutting edges and deduce the mathematicalexpressions of the local cutting angles and cutting parameters. Every discrete cutting elementcan be considered as an improved oblique cutting process, which takes into account theinteraction between the chip elements. The relationship of the global chip flow angle and the turning force can be derived based on force equilibrium of each local chip element and theglobal chip. The proposed model has been applied to predict and analyse the turning force inthe three distinct cases, especially in the case of non-free factors of the corner radius and maincutting edge angle. The chip flow in turning may scratch the machined surface, under thecircumstances, the surface will have a poor quality. We investigated the influence of the tooland cutting parameters on the local and global chip flow angle. The results helpmanufacturing engineers to choose the cutting angle, nose radius and cutting depth to controlchip flow direction towards the outside of the workpiece axis. Finally, the tool and cuttingparameter effect on the local geometric and physical parameters along the cutting edge areconsidered as coupled. These local information is important to the optimization of cuttingparameters and the cutting edge geometry.
The proposed method in this dissertation has been implemented in Matlab7.0. Based on aset of orthogonal cutting tests, the material and friction coefficients are indentified. Predictedresults were compared with experiment results of cutting forces for304stainless steel andfound in reasonable agreement. So this model can be used to analyse the cutting process of thenuclear reactor coolant pump. This model is also validated by the experimental results ofother materials, such as literature results of42CrMo4steel and316L stainless steel, millingexperimental results of45steel. It should be noted that although this work is limited tomilling and turning, the present method also be applied to other machining operations such asdrilling and boring.
引文
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