错齿BTA深孔钻削切屑变形及刀屑接触长度分布规律研究
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摘要
断排屑问题一直是错齿BTA内排屑深孔钻削的难点,通过建立切屑流经断屑台的几何变形模型分析了刀屑接触长度对错齿BTA钻削切屑的变形断裂的影响,采用有限元分析软件DEFORM-3D建立了错齿BTA钻头钻削仿真模型,对各刀齿切屑的形成及变形规律进行了分析,研究了刀屑接触长度随刀齿钻削半径分布规律及其随钻削条件的变化规律,并利用实验对仿真结果进行了验证分析。结果表明,仿真结果可信,刀齿钻削半径对切屑的变形及刀屑接触长度影响很大,刀屑接触长度随钻削进给量增大而增大,随转速增大而减小,随工件材料强度增大而增大。
It is difficult to resolve the chip breaking and discharge in the staggered teeth boring and trepanning association( BTA) drilling. The effect of the tool-chip contact length on chip deformation and breaking in the staggered teeth BTA drilling is analyzed with the geometric deformation model of chip breaking we built in the paper. We adopt the finite element method( FEM) simulation software of DEFORM-3 D to establish the drilling model for simulation. The rules that govern formation and deformation of every cutting tooth chipping are analyzed;the distribution laws with the drilling radius and drilling condition of the tool-chip contact length are studied. The simulation results are verified by experiments. The results show that the simulation is reliable. The drilling radius has a great influence on the deformation of chips and tool-chip contact length. The tool-chip contact length of the cutting teeth increases with the increase of the feed and material strength and the decrease of the speed.
It is difficult to resolve the chip breaking and discharge in the staggered teeth boring and trepanning association( BTA) drilling. The effect of the tool-chip contact length on chip deformation and breaking in the staggered teeth BTA drilling is analyzed with the geometric deformation model of chip breaking we built in the paper. We adopt the finite element method( FEM) simulation software of DEFORM-3 D to establish the drilling model for simulation. The rules that govern formation and deformation of every cutting tooth chipping are analyzed;the distribution laws with the drilling radius and drilling condition of the tool-chip contact length are studied. The simulation results are verified by experiments. The results show that the simulation is reliable. The drilling radius has a great influence on the deformation of chips and tool-chip contact length. The tool-chip contact length of the cutting teeth increases with the increase of the feed and material strength and the decrease of the speed.
引文
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[2]孔令飞,牛晗,侯晓丽,等.错齿内排屑刀具深孔加工中的刀具振动特性对孔圆度形貌的作用机制[J].兵工学报,2016,37(6):1066-1074Kong L F,Niu H,Hou X L,et al. Influence of tool vibration characteristics on the hole roundness morphology in BTA deep-hole drilling[J]. Acta Armamentarii,2016,37(6):1066-1074(in Chinese)
[3]王培河.AP1000蒸汽发生器制造难点分析[J].中国核电,2011,4(1):52-59Wang P H. Manufacturing difficulties analysis of AP1000 steam generator[J]. China Nuclear Power,2011,4(1):52-59(in Chinese)
[4] Thil J,Haddag B,Nouari M,et al. Experimental and analytical analyses of the cutting process in the deep hole drilling with BTA(Boring Trepanning Association)system[J]. Mechanics&Industry, 2013,14(6):413-429
[5] Sahu S K,De Vor R E,Kapoor S G. Modeling of forces for drills with chip-breaking grooves[J]. Journal of Manufacturing Science and Engineering,2004,126(3):555-564
[6]宋金玲,魏天路,顾立志.金属切削中刀-屑接触长度的有限元分析[J].农业机械学报,2003,34(3):118-121Song J L,Wei T L,Gu L Z. Finite element analysis for tool-chip contact length in metal machining[J].Transactions of the Chinese Society of Agricultural Machinery,2003,34(3):118-121(in Chinese)
[7] Tnay G L,Wan S,Woon K S,et al. The effects of duboff angle on chip evacuation in single-lip deep hole gun drilling[J]. International Journal of Machine Tools and Manufacture,2016,108:66-73
[8]杨翔,郑建明,李旭波,等.错齿BTA钻头刀体扭转强度模拟分析与实验研究[J].机械科学与技术,2017,36(3):391-396Yang X,Zheng J M,Li X B,et al. Simulation and experimental study on torsion strength of staggered BTA drill body[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(3):391-396(in Chinese)
[9] Biermann D,Kirschner M. Experimental investigations on single-lip deep hole drilling of superalloy Inconel 718with small diameters[J]. Journal of Manufacturing Processes,2015,20:332-339
[10] Gao C H,Cheng K,Kirkwood D. The investigation on the machining process of BTA deep hole drilling[J].Journal of Materials Processing Technology,2001,107(1-3):222-227
[11] Ke F,Ni J,Stephenson D A. Chip thickening in deephole drilling[J]. International Journal of Machine Tools and Manufacture,2006,46(12-13):1500-1507
[12] Fang N. Machining with tool-chip contact on the tool secondary rake face-Part I:a new slip-line model[J].International Journal of Mechanical Sciences,2002,44(11):2337-2354
[13] Shinozuka J,Obikawa T,Shirakashi T. Chip breaking analysis from the viewpoint of the optimum cutting tool geometry design[J]. Journal of Materials Processing Technology,1996,62(4):345-351
[14]程凤军,陈国定,王涛.Deform 3D软件支持的球头铣刀铣削仿真分析[J].机械科学与技术,2012,31(3):412-416Cheng F J,Chen G D,Wang T. The simulation analysis for the milling process of ball end mill using the deform3D[J]. Mechanical Science and Technology for Aerospace Engineering, 2012,31(3):412-416(in Chinese)
[15]陈刚,陈小伟,陈忠富,等.A3钢钝头弹撞击45钢板破坏模式的数值分析[J].爆炸与冲击,2007,27(5):390-397Chen G,Chen X W,Chen Z F,et al. Simulations of A3steel blunt projectiles impacting 45 steel plates[J].Explosion and Shock Waves,2007,27(5):390-397(in Chinese)