超声椭圆振动切削钛合金切削力特性研究
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摘要
利用超声椭圆振动切削(UEVC)对TC4钛合金切削力特性进行了研究。基于ABAQUS力-热耦合模型分析了超声椭圆振动切削钛合金的瞬态切削过程,模拟在不同切深和切削速度下的瞬态切削情况,提取和对比普通切削(CC)和超声椭圆振动切削的主切削力,进而进行数据处理,分析两者主切削力对比情况和平均主切削力之差的变化。研究分析表明:在椭圆振动切削下,切削力减小比率随着切深的增加而减小,随着切削速度的增大而增大。最后进行试验验证,实验结论与仿真结果一致。对超声振动切削难加工材料钛合金时切削用量的选择提供了参考。
Here, the characteristics of cutting force were studied when the ultrasonic elliptical vibration cutting(UEVC) method was used to process TC4 titanium alloy. The transient cutting processes of titanium alloy with UEVC method were numerically simulated based on the force-thermal coupled model in the finite element(FE) software ABAQUS under different cutting depths and cutting speeds, and extract the main cutting forces. The main cutting forces of UEVC were compared with those of the conventional cutting(CC), and the data processing was done for them to analyze differences between the two main cutting forces and their variation. The study and analysis showed that Under UEVC, the reduction rate of cutting forces decreases with increase in cutting depth, and increases with increase in cutting speed. Finally, tests were conducted to verify the simulation results, and the test results agreed well with those of simulation. The results provided a reference for choosing cutting amount during titanium alloy processed with UEVC.
Here, the characteristics of cutting force were studied when the ultrasonic elliptical vibration cutting(UEVC) method was used to process TC4 titanium alloy. The transient cutting processes of titanium alloy with UEVC method were numerically simulated based on the force-thermal coupled model in the finite element(FE) software ABAQUS under different cutting depths and cutting speeds, and extract the main cutting forces. The main cutting forces of UEVC were compared with those of the conventional cutting(CC), and the data processing was done for them to analyze differences between the two main cutting forces and their variation. The study and analysis showed that Under UEVC, the reduction rate of cutting forces decreases with increase in cutting depth, and increases with increase in cutting speed. Finally, tests were conducted to verify the simulation results, and the test results agreed well with those of simulation. The results provided a reference for choosing cutting amount during titanium alloy processed with UEVC.
引文
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[11] 董辉跃.航空整体结构件加工过程的数值仿真[D].杭州:浙江大学,2004.
[12] 孙杰.航空整体结构件数控加工变形校正理论和方法研究[D].杭州:浙江大学,2003.
[13] 汤敬计.超精密切削过程的有限元仿真[D].哈尔滨:哈尔滨工业大学,2004.
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[17] PATIL S,JOSHI S,TEWARI A,et al.Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V[J].Ultrasonics,2014,54(2):694-705.
[18] 隈部淳一郎.精密加工振动切削[M].北京:机械工业出版社,1989.
[19] PANTALé O,BACARIA J L,DALVEMY O,et al.2D and 3D numerical models of metal cutting with damage effects[J].Computer Methods in Applied Mechanics & Engineering,2004,193:4383-4399.
[20] MOLINARI A,MUSQUAR C,SUTTER G.Adiabatic shear banding in high speed machining of Ti-6Al-4V:experiments and modeling[J].International Journal of Plasticity,2002,18(4):443-459.
[21] KAY.Failure modeling of Titanium6Al4V and 2024-T3 Aluminum with the Johnson-Cook material model[R].Springfield,VA:Nation Technical Information Service(NTIS),2003:1-24.
[22] 赵威,何宁,李亮.强化冷却下正交切削Ti6Al4V合金的有限元分析[J].华南理工大学学报 (自然科学版),2006,34(7):40-44.ZHAO Wei,HE Ning,LI Liang.Finite element analysis of orthogonal cutting of Ti6Al4V alloy in enhanced cooling condition[J].Journal of South China University of Technology(Natural Science Edition),2006,34(7):40-44.
[23] 姚永琪,郭乙木,朱凌,等.高速切削时摩擦因数对切削影响的数值模拟[J].工程设计学报,2004,11(1):31-36.YAO Yongqi,GUO Yimu,ZHU Ling,et al.Numerical simulation for effect of friction coefficient under high-speed cutting by FEA[J].Journal of Engineering Design,2004,11(1):31-36.
[24] 孟龙.钛合金高速铣削过程建模[D].上海:上海交通大学,2013.
[2] PRATAP T,PATRA K,DYAKONOV A A.Modeling Cutting Force in Micro-Milling of Ti-6Al-4V Titanium Alloy[J].Procedia Engineering,2015,129:134-139.
[3] SUI H,ZHANG X,ZHANG D,et al.Feasibility study of high-speed ultrasonic vibration cutting titanium alloy[J].Journal of Materials Processing Technology,2017,247(19):120-127.
[4] HARADA K,SASAGARA H.Effect of dynamic response and displacement/stress amplitude on ultrasonic vibration cutting[J].Journal of Materials Processing Technology,2009,209(9):4490-4495.
[5] 唐军.碳/碳化硅材料纵扭复合超声铣削系统及加工稳定性的研究[D].焦作:河南理工大学.2015.
[6] XIAO M,SATO K,KARUBE S,et al.The effect of tool nose radius in ultrasonic vibration cutting of hard metal[J].International Journal of Machine Tools & Manufacture,2003,43(13):1375-1382.
[7] 牛赢.硬质合金激光超声辅助切削刀具磨损特性研究[D].焦作:河南理工大学,2014.
[8] DUCOBU F,ARRAZOLA P J,RIVIERE-LORPHEVRE E,et al.Finite element prediction of the tool wear influence in Ti6Al4V machining[J].Procedia Cirp,2015,31:124-129.
[9] 杨勇,柯映林,董辉跃,等.金属切削加工中航空铝合金板材的本构模型[J].中国有色金属学报,2005,15(6):854-859.YANG Yong,KE Yinglin,DONG Huiyue,et al.Constitutive model of aviation aluminum-alloy materialin metal machining[J].The Chinese Journal of Nonferrous Metals,2005,15(6):854-859.
[10] 黄志刚,柯映林,王立涛.金属切削加工的热力耦合模型及有限元模拟研究[J].航空学报,2004,25(3):317-320.HUANG Zhigang,KE Yinglin,WANG Litao.Coupled thermo-mechanical model for metal orthogonal cutting process and finite element simulation[J].Acta Aeronautica et Astronautica Sinica,2004,25(3):317-320.
[11] 董辉跃.航空整体结构件加工过程的数值仿真[D].杭州:浙江大学,2004.
[12] 孙杰.航空整体结构件数控加工变形校正理论和方法研究[D].杭州:浙江大学,2003.
[13] 汤敬计.超精密切削过程的有限元仿真[D].哈尔滨:哈尔滨工业大学,2004.
[14] 李国宾.微细金属切削加工过程有限元仿真实验研究[D].天津:天津大学,2010.
[15] ALI M H,KHIDHIR B A,ANSARI M N M,et al.FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy[J].HBRC Journal,2013,9(3):263-269.
[16] MUHAMMAD R,AHMED N,DEMIRA M,et al.Computational study of ultrasonically-assisted turning of Ti alloys[J].Advanced Materials Research,2011,223:30-36.
[17] PATIL S,JOSHI S,TEWARI A,et al.Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V[J].Ultrasonics,2014,54(2):694-705.
[18] 隈部淳一郎.精密加工振动切削[M].北京:机械工业出版社,1989.
[19] PANTALé O,BACARIA J L,DALVEMY O,et al.2D and 3D numerical models of metal cutting with damage effects[J].Computer Methods in Applied Mechanics & Engineering,2004,193:4383-4399.
[20] MOLINARI A,MUSQUAR C,SUTTER G.Adiabatic shear banding in high speed machining of Ti-6Al-4V:experiments and modeling[J].International Journal of Plasticity,2002,18(4):443-459.
[21] KAY.Failure modeling of Titanium6Al4V and 2024-T3 Aluminum with the Johnson-Cook material model[R].Springfield,VA:Nation Technical Information Service(NTIS),2003:1-24.
[22] 赵威,何宁,李亮.强化冷却下正交切削Ti6Al4V合金的有限元分析[J].华南理工大学学报 (自然科学版),2006,34(7):40-44.ZHAO Wei,HE Ning,LI Liang.Finite element analysis of orthogonal cutting of Ti6Al4V alloy in enhanced cooling condition[J].Journal of South China University of Technology(Natural Science Edition),2006,34(7):40-44.
[23] 姚永琪,郭乙木,朱凌,等.高速切削时摩擦因数对切削影响的数值模拟[J].工程设计学报,2004,11(1):31-36.YAO Yongqi,GUO Yimu,ZHU Ling,et al.Numerical simulation for effect of friction coefficient under high-speed cutting by FEA[J].Journal of Engineering Design,2004,11(1):31-36.
[24] 孟龙.钛合金高速铣削过程建模[D].上海:上海交通大学,2013.