基于三大变形区的车削SiCp/Al复合材料切削力理论分析方法
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摘要
为了准确预测Si Cp/Al复合材料车削时的切削力,在充分考虑了Si C颗粒对铝基体影响的基础上,提出一种较为新颖的切削力理论分析方法。方法建立在正交切削模型基础上,将切削力产生归结于3个来源,即剪切变形区、前刀面摩擦区和犁耕区,分析了剪切变形力、前刀面的滑动/滚动摩擦力和犁耕力,并分别将之分解为X、Y、Z方向的力。为了验证该方法的有效性,利用PCD车刀和CA6140A车床,进行了50%的SiCp/Al复合材料的车削实验。结果表明,该切削力理论分析方法在一定的切削参数条件下能够较准确的预测切削力。
To predict the cutting force of cutting Si C particle reinforced aluminum-based compositeaccurately,an innovative theoreticalanalytical method is proposed in consideration of the influence of Si C particles on aluminum substrate. This method is built on the orthogonal cutting model,cutting force is considering to derive from threedeformed zones,namely,primary shear zone,primary friction zone andplough zone. Shear force,sliding and rolling friction force and plough force is analyzed based on the three deformation area,which is decomposed in X,Y,Z direction. To verify the validity of this method,turning experiments on 50% particles Si Cp/Al composites are conducted on CA6140 A turning-lathe by using PCD cutting tool. Experimental results show that the analytical methodcan be used to predict the cutting force accuratelyon the conditions of some cutting parameters.
To predict the cutting force of cutting Si C particle reinforced aluminum-based compositeaccurately,an innovative theoreticalanalytical method is proposed in consideration of the influence of Si C particles on aluminum substrate. This method is built on the orthogonal cutting model,cutting force is considering to derive from threedeformed zones,namely,primary shear zone,primary friction zone andplough zone. Shear force,sliding and rolling friction force and plough force is analyzed based on the three deformation area,which is decomposed in X,Y,Z direction. To verify the validity of this method,turning experiments on 50% particles Si Cp/Al composites are conducted on CA6140 A turning-lathe by using PCD cutting tool. Experimental results show that the analytical methodcan be used to predict the cutting force accuratelyon the conditions of some cutting parameters.
引文
[1]Kishawy HA,Kannan S,Balazinski M.An energy based force model for orthogonal cutting of metal matrix composites[J].Annals of the CIRP,2004,53(1):91-94.
[2]Pramanik A,Zhang LC,Arsecularatne JA.Prediction of cutting forces in machining of metal matrixcomposites[J].International Journal of Machine Tools&Manufacture,2006,46(16):1795-1803.
[3]Dabade UA,Dapkekar D,Joshi,SS.Modeling of chip-tool interfacefriction to predict cutting forces in machining of Al/Si Cp composites[J],International Journal of Machine Tools&Manufacture,2009,49(9):690-700.
[4]边卫亮,傅玉灿,徐九华,等.Si Cp/Al复合材料高速铣削切削力模型建立[J].航空制造技术,2012(3):92-95.BIANWei Liang,FU Yu Can,XU Jiu Hua,et al.High-speed millingforce model for Si Cp/Al composites[J].Aeronautical Manufacturing Technology,2012(3):92-95(In Chinese).
[5]Du J G,Li JG,Yao Y X,et al.Prediction of cutting forces in millgrinding Si Cp/Al composites[J],Materials and Manufacturing Processes,2014,29(3):314-320.
[6]王进峰,储开宇,赵久兰,等.Si Cp/Al复合材料切削仿真及实验研究[J].人工晶体学报,2016,45(7):1756-1964.WANG Jin Feng,CHU Kai Yu,ZHAO Jiu Lan,et al.Cutting simulation and experiment of Si Cp/Al composites[J].Journal of Synthetic Crystals,2016,45(7):1756-1964(In Chinese).
[7]叶贵根,薛世峰,仝兴华,等.金属正交切削模型研究进展[J].机械强度,2012,34(4):531-544.YE Gui Gen,XUE Shi Feng,TONG Xing Hua,et al.Advances in orthogonal cutting models[J].Journal of Mechanical Strength,2012,34(4):531-544(In Chinese).
[8]Cronjager L,Meister D.Machining of fibre and particle reinforced aluminium[J],Annals of the CIRP,1992,41(1):63-66.
[9]汪志城.滚动摩擦机理和滚动摩擦系数[J].上海机械学院学报,1993,15(4):35-43.WANG Zhi Cheng.A mechanism of rolling friction and the coefficient of rolling friction[J].Journal of Shanghai Institution of Mechanical Engineering,1993,15(4):35-43(In Chinese).
[10]魏勤,骆英.超声法研究Si C体积比对Si Cp/Al复合材料力学性能的影响[J].机械强度,2011,33(2):179-182.WEI Qin,LUO Ying.Influence of Si Cvolume fraction on mechanical properties of Si Cp Al composite by ultrasonic method[J].Journal of Mechanical Strength,2011,33(2):179-182(In Chinese).
[11]肖代红,黄伯云.增强体颗粒失效对Si Cp/Al复合材料屈服强度的影响[J].机械强度,2008,30(6):953-958.XIAO Dai Hong HUANG Bai Yun.Effect of particle failure on the yield strength of Si Cp/Al matrix composites[J].Journal of Mechanical Strength,2008,30(6):953-958(In Chinese).
[2]Pramanik A,Zhang LC,Arsecularatne JA.Prediction of cutting forces in machining of metal matrixcomposites[J].International Journal of Machine Tools&Manufacture,2006,46(16):1795-1803.
[3]Dabade UA,Dapkekar D,Joshi,SS.Modeling of chip-tool interfacefriction to predict cutting forces in machining of Al/Si Cp composites[J],International Journal of Machine Tools&Manufacture,2009,49(9):690-700.
[4]边卫亮,傅玉灿,徐九华,等.Si Cp/Al复合材料高速铣削切削力模型建立[J].航空制造技术,2012(3):92-95.BIANWei Liang,FU Yu Can,XU Jiu Hua,et al.High-speed millingforce model for Si Cp/Al composites[J].Aeronautical Manufacturing Technology,2012(3):92-95(In Chinese).
[5]Du J G,Li JG,Yao Y X,et al.Prediction of cutting forces in millgrinding Si Cp/Al composites[J],Materials and Manufacturing Processes,2014,29(3):314-320.
[6]王进峰,储开宇,赵久兰,等.Si Cp/Al复合材料切削仿真及实验研究[J].人工晶体学报,2016,45(7):1756-1964.WANG Jin Feng,CHU Kai Yu,ZHAO Jiu Lan,et al.Cutting simulation and experiment of Si Cp/Al composites[J].Journal of Synthetic Crystals,2016,45(7):1756-1964(In Chinese).
[7]叶贵根,薛世峰,仝兴华,等.金属正交切削模型研究进展[J].机械强度,2012,34(4):531-544.YE Gui Gen,XUE Shi Feng,TONG Xing Hua,et al.Advances in orthogonal cutting models[J].Journal of Mechanical Strength,2012,34(4):531-544(In Chinese).
[8]Cronjager L,Meister D.Machining of fibre and particle reinforced aluminium[J],Annals of the CIRP,1992,41(1):63-66.
[9]汪志城.滚动摩擦机理和滚动摩擦系数[J].上海机械学院学报,1993,15(4):35-43.WANG Zhi Cheng.A mechanism of rolling friction and the coefficient of rolling friction[J].Journal of Shanghai Institution of Mechanical Engineering,1993,15(4):35-43(In Chinese).
[10]魏勤,骆英.超声法研究Si C体积比对Si Cp/Al复合材料力学性能的影响[J].机械强度,2011,33(2):179-182.WEI Qin,LUO Ying.Influence of Si Cvolume fraction on mechanical properties of Si Cp Al composite by ultrasonic method[J].Journal of Mechanical Strength,2011,33(2):179-182(In Chinese).
[11]肖代红,黄伯云.增强体颗粒失效对Si Cp/Al复合材料屈服强度的影响[J].机械强度,2008,30(6):953-958.XIAO Dai Hong HUANG Bai Yun.Effect of particle failure on the yield strength of Si Cp/Al matrix composites[J].Journal of Mechanical Strength,2008,30(6):953-958(In Chinese).