基于DEFORM-3D软件模拟7075铝合金切削力及其断裂准则的选择
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摘要
建立了7075铝合金有限元切削模型,利用DEFORM-3D软件基于默认断裂准则模拟了在切削过程中切削力的变化,并进行了试验验证;采用此切削模型,分别在Freudenthal、Cockcroft-Latham、Normalized和Ayada断裂准则下进行了切削力模拟,分析了不同断裂准则的适用性。结果表明:在默认断裂准则下模拟得到的平均切削力与测试值的相对误差在10%以内,验证了有限元切削模型的准确性;采用Freudenthal断裂准则模拟得到的平均切削力与测试值的相对误差较大,而Cockcroft-Latham、Normalized和Ayada断裂准则模拟得到的相对误差均在9%以内;Ayada断裂准则最适合用于模拟7075铝合金的切削过程,其次为Cockcroft-Latham和Normalized断裂准则。
The finite element cutting model of 7075 aluminum alloy was established,and the change of cutting force in cutting process was simulated by DEFORM-3D software with the default fracture criterion,and verified by experiments.The cutting model was used to simulate the cutting forces with Freudenthal,CockcroftLatham,Normalized and Ayada fracture criteria,respectively,and the applicability of the different fracture criteria was analyzed.The results show that the relative error between the simulated average cutting force and the measured value with the default fracture criterion was below 10%,verifying the accuracy of the finite element cutting model.The relative error between the average cutting force simulated with Freudenthal fracture criterion and the measured value was relatively large,whereas the relative errors with Cockcroft-Latham,Normalized and Ayada fracture criteria were all within 9%.Ayada fracture criterion was the most suitable for simulating the cutting of 7075 aluminum alloy,followed by Cockcroft-Latham and Normalized fracture criteria.
The finite element cutting model of 7075 aluminum alloy was established,and the change of cutting force in cutting process was simulated by DEFORM-3D software with the default fracture criterion,and verified by experiments.The cutting model was used to simulate the cutting forces with Freudenthal,CockcroftLatham,Normalized and Ayada fracture criteria,respectively,and the applicability of the different fracture criteria was analyzed.The results show that the relative error between the simulated average cutting force and the measured value with the default fracture criterion was below 10%,verifying the accuracy of the finite element cutting model.The relative error between the average cutting force simulated with Freudenthal fracture criterion and the measured value was relatively large,whereas the relative errors with Cockcroft-Latham,Normalized and Ayada fracture criteria were all within 9%.Ayada fracture criterion was the most suitable for simulating the cutting of 7075 aluminum alloy,followed by Cockcroft-Latham and Normalized fracture criteria.
引文
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[4]夏亮亮,袁军堂,汪振华,等.基于DEFORM-3D的铝合金铣削力仿真与试验研究[J].机械设计与制造,2013(4):85-87.
[5]VINOGRADOVA A.On the mechanism of chip formation in oblique cutting of metals[J].Journal of Superhard Materials,2014,36(6):428-434.
[6]BUCHKREMER S,KLOCKE F,VESELOVAC D.3DFEMsimulation of chip breakage in metal cutting[J].International Journal of Advanced Manufacturing Technology,2016,82(1/2/3/4):645-661.
[7]黄勇,狄欧,李亚非,等.基于Deform-3D的铝合金2A12车削加工有限元模拟[J].机械制造,2016,54(6):41-43.
[8]魏效玲,王剑锋.基于DEFORM的刀具几何参数与切削力关系的研究[J].组合机床与自动化加工技术,2014(11):11-13.
[9]张方东.基于Deform 45钢切削力仿真研究[J].内燃机与配件,2016(10):56-58.
[10]王海涛.6061铝合金高速铣削有限元仿真与实验研究[D].青岛:青岛理工大学,2015.
[11]李智,刘彦伯.金属薄壁零件切削过程的三维仿真[J].工具技术,2016,50(5):49-52.
[12]李娜.金属切削过程刀-屑接触区摩擦状态有限元分析[D].秦皇岛:燕山大学,2009.
[13]胡艳娟,王占礼,朱丹,等.基于DEFORM-3D的金属铣削过程仿真研究[J].制造技术与机床,2014(1):94-99.
[14]李智,李俊涛,郭峰,等.基于Deform-3D的金属切削力仿真分析[J].装备制造技术,2016(1):17-20.
[15]艾兴,肖诗纲.切削用量简明手册[M].北京:机械工业出版社,1994.
[16]占刚,何林,蒋宏婉,等.断裂准则对AISI-1045切削仿真的影响及选择[J].组合机床与自动化加工技术,2016(4):16-20.
[17]刘东,尹婷.锯齿形切屑断裂准则的有限元仿真研究[J].机械设计与制造,2014(10):203-205.