三维复杂槽型铣刀片切入类型理论分析及其开发研究
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摘要
本文来源于黑龙江省重大科技攻关项目:“大型、复杂零部件用现代刀具系列产品化与开发研究”课题中的一个子项。以研究波形刃铣刀片的切入类型的理论分析及其开发研究为主要内容。
本文在总结M.Kronenberg接触法和林树兴的解析计算法基础上,推导了前刀面方程及其运动方程、主切削刃旋转所形成的曲面方程、前刀面运动时与工件切入侧面的接触线LM方程以及切削表面与工件侧表面交线C1D1方程,最后推导了八种切入类型判别式,上述成果为将来进一步研究三维复杂槽型铣刀片的切入破损打下理论基础。
本文对不同切入类型的波形刃铣刀片的切削力进行了比较试验,同时用功率谱分析对波形刃不同切入类型的波形刃铣刀片进行了动态铣削波形的特性分析,从而进行切入类型的优选。
本文对采用不同材质、槽型的波形刃铣刀片切削不同工件材料进行切削力对比试验研究。采用超细晶粒材质铣刀片和4030、4040切削45号钢和不锈钢进行切削力对比试验研究;并在电机厂对上述刀片进行寿命对比试验研究。
最后,本文对车铣两用圆刀片的切屑形成、卷曲、流向机理进行了初步的研究。
This is the sub-subject“The modern cutters on large and complex part are series manufactured and researched”of Heilongjiang province great science and technology tackle key problem item, which is mainly about the study of face milling cutter cut-in type.
Based on summarizing the contact method of M.Kronenberg and the parse calculation method of Shuxing Lin, this thesis concluded the equation of the face and its movement equation, the curved surface equation produced by main cutting edge circumgyratting, the equation of the contact line LM produced when the face cutting-in the side face of the workpiece and the equation of the intersectant line C1D1 produced by the cutting surface and the workpiece side face, at last, the discriminant of the eight cutting-in manner were concluded, All the production above are the theory foundation for further researching the cutting-in disrepair of the 3-D complex groove insert..
This thesis contrasted the cutting force of the wave-edge with different cutting-in manner, synchronously, the wave characteristic of the dynamic milling was analysed used the power spectrum analysis for wave-edge insert with different cutting-in manner and optimized choosing the cut-in type consequently.
This thesis researched the cutting force contrast when cutting the work pieces made of different material used wave-edge insert made of different material. experimented and contrasted the cutting force produced by cutting the 45 steel and the stainless steel used the Ultra-fine grain insert ,4030 insert, and 4050 insert, and experimented and contrasted the life-span for the inserts introduced above in HEC.
Finally, the thesis primary research the mechanism of chip’s forming, curling and flowing direction used the round insert which can be used in milling and turning.
本文在总结M.Kronenberg接触法和林树兴的解析计算法基础上,推导了前刀面方程及其运动方程、主切削刃旋转所形成的曲面方程、前刀面运动时与工件切入侧面的接触线LM方程以及切削表面与工件侧表面交线C1D1方程,最后推导了八种切入类型判别式,上述成果为将来进一步研究三维复杂槽型铣刀片的切入破损打下理论基础。
本文对不同切入类型的波形刃铣刀片的切削力进行了比较试验,同时用功率谱分析对波形刃不同切入类型的波形刃铣刀片进行了动态铣削波形的特性分析,从而进行切入类型的优选。
本文对采用不同材质、槽型的波形刃铣刀片切削不同工件材料进行切削力对比试验研究。采用超细晶粒材质铣刀片和4030、4040切削45号钢和不锈钢进行切削力对比试验研究;并在电机厂对上述刀片进行寿命对比试验研究。
最后,本文对车铣两用圆刀片的切屑形成、卷曲、流向机理进行了初步的研究。
This is the sub-subject“The modern cutters on large and complex part are series manufactured and researched”of Heilongjiang province great science and technology tackle key problem item, which is mainly about the study of face milling cutter cut-in type.
Based on summarizing the contact method of M.Kronenberg and the parse calculation method of Shuxing Lin, this thesis concluded the equation of the face and its movement equation, the curved surface equation produced by main cutting edge circumgyratting, the equation of the contact line LM produced when the face cutting-in the side face of the workpiece and the equation of the intersectant line C1D1 produced by the cutting surface and the workpiece side face, at last, the discriminant of the eight cutting-in manner were concluded, All the production above are the theory foundation for further researching the cutting-in disrepair of the 3-D complex groove insert..
This thesis contrasted the cutting force of the wave-edge with different cutting-in manner, synchronously, the wave characteristic of the dynamic milling was analysed used the power spectrum analysis for wave-edge insert with different cutting-in manner and optimized choosing the cut-in type consequently.
This thesis researched the cutting force contrast when cutting the work pieces made of different material used wave-edge insert made of different material. experimented and contrasted the cutting force produced by cutting the 45 steel and the stainless steel used the Ultra-fine grain insert ,4030 insert, and 4050 insert, and experimented and contrasted the life-span for the inserts introduced above in HEC.
Finally, the thesis primary research the mechanism of chip’s forming, curling and flowing direction used the round insert which can be used in milling and turning.
引文
1 Leading Edge Group. Industry News: Machine Tool Markets Analyzed. Cutting Tool Engineering,1996,48(5): 2~4
2 胡红兵. 1991-1995 年中国工具工业概况. 工具展望,1997,(1): 1~6
3 沈壮行. 工具工业面临的严重挑战和发展对策. 工具展望,1995,(4): 1~8
4 陈昆. 国内工具产品市场分析. 工具展望,1996,(3): 1~3
5 沈壮行. 中国工具工业的发展为什么赶不上制造业的需要——发展状况、问题浅谈和改进建议.机械工人, 2002,(9): 9~10
6 程伟. 切削加工和刀具技术的现状与发展. 工具展望, 2002,36(123): 3~6
7 M.Kronenberg.Initial Contact of Milling Cutter and Work-piece.MACHINERY, 1945:149~156
8 M.Kronenberg.Analysis of Initial contact of Milling Cutter and Work in Relation to Tool Life.ASME,1946:217~228
9 Opitz H,Beckhaus H.Influence of Initial Contact on Tool Life When Face Milling High Strength Materials. CIRP,1970 30(2):50~62
10 R. Werheim, A. Satron and A. Ber. Modifications of the Cutting Edge Geometry and Chip Formation in Milling. Annals of the CIRP,1994, 43(1): 63~68
11 The Association for Manufacturing Technology.IMTS96: What’s in the Mix for 96. Cutting Tool Engineering. 1996,48(5): 4~11
12 T. Hoshi. Development of High-performance Machining Technologies. International Conference on Machining Technology in Asian & Pacific Regions. Guangzhou,1993: 24~30
13 竹山秀彦,山田皓一.炭素钢 S50C の超硬正面フヲィス削リ.精密机械,1981,26(11):51~60
14 竹山,山田.合金钢 SNCM8(热处理)の超硬正面フヲィス削リ.精密机械,1983,29(6):83~102
15 竹山,山田.オ一ステナィナト不锈钢(SUS27)の超硬正面フヲィス削リ.精密机械,1982,30(2):65~90
16 于彦波等.硬质合金刀具断续切削破损理论. 华中理工大学出版社,1989,1~4
17 于彦波,王志勇.端铣刀切入破损机理的研究.哈尔滨科技大学学报,1987(3)
18 林树兴.面铣刀前刀面接触点计算的新方法.渝州大学学报,1995,12(1):26~31
19 张中民, 徐亦红, 李振加等. 圆形刀片切屑流向的试验研究[J]. 哈尔滨科学技术大学学报, 1996,20(2): 12~14
20 李振加,郑敏利,徐亦红,曲贵民.切屑折断过程研究[M]. 机械工业出版社, 1996
21 苏金明. MATLAB6.1 使用指南(下册)[M].电子工业出版社,2002
22 胡庆军,吴翊,李永乐. 应用数理统计.国防科技大学出版社[M], 2003
23 达世亮.汽车工业切削与刀具技术现状.工具技术,2004,38(9):38~42
24 赵炳桢.切削技术与刀具工业的新时代.工具技术,2004,38(9):24~26
25 井原透, 白坚高洋, 臼井英治. 断续切削における切れ刃欠损の解析的予测に关する研究(第 4 报). 精密机械.,1982,48(6): 71~77
26 N。Alfrli,The Efferfs of the Fracture Chipping and Wear of Cemented Carbide Tools on the Determination of the optimun Metal-Cutting Coneitions. Annals of the CIRP ,1981,30(1):68~81
27 刘战强,李兆前,艾兴.硬质合金刀具寿命分布规律的研究.硬质合金,1995,12(1):7~10
28 伊兵.粗加工模块式端铣刀及其破损机理的研究.哈尔滨科技大学硕士论文,1989
29 魏宗舒.概率论与数理统计教程.高等教育出版社,1999
30 姚英学,等.平头立铣刀铣削力模型中积分限的确定方法.工具技术,2004(38):11~13
31 李振加,等.波形刃铣刀片的开发及其铣削力数学模型[J].机械工程学报,2000,36(10):42-45
32 白新桂.数据分析与试验优化设计.清华大学出版社,1986
33 赵鸿.模块式重型车刀系统的研究.哈尔滨科技大学硕士论文.1988
34 B. Ghahramani, Z. Y.Wang, C. Sahay, K. P. Rajurkar. Analysis of Initial Contact and Tool Fracture in the Milling Process. Machining Science and Technology, 1999,3(1): 9~23
35 P. Lee, Y. Altintas. Prediction of Ball-end Milling Forces From Orthogonal Cutting Data. Int. J. Mach. Tools & Manufact., 1996,36(9): 1269~1290
36 H. Q. Zheng et al. Theoretical modeling and simulation of cutting forces in facemilling with cutter runout. Int. J. Mach. Tools & Manufact , 39(1999): 2003~2018
37 李振加,等.切屑空间运动轨迹及其约束方程的研究[J].机械工程学报,2001,37(12):42-46
38 李振加等. 铣削过程刀具破损原因的探讨. 机械工程学报,1993,29(4): 93~96
39 郑敏利. 模块式面铣刀合理几何参数实验研究. 哈尔滨电工学院学报.,1996,(2): 153~175
40 李振加等. 硬质合金刀具的粘结破损机理. 哈尔滨科学技术大学学报, 1993,17(3): 11~13
41 Fenglian, Sun. Adhering Wear Mechanism of Cemented Carbide Cutter in the Intervallic Cutting of Stainless Steel. Wear,1998,(214): 79~82
42 Zhenjia, Li. Waved-edge Insert Development and Milling Force Model. ICPCG’2000,2000
43 Zhenjia, Li. Milling Force Mode of Three-Dimensional Complex Groove Insert. IMCC’2000.,2000
44 Zhenjia, Li. Research on Sticking-welding Fracture Mechanism For cutter by Analyzing Three-Dimensional Stress Field. IMCC’95
45 Lihua, Dong. Study on Milling Properties of Three-Dimensional Complex Groove. 15th International Conference on Production Research Ireland,1999
46 陶海虹. 三维复杂槽型铣刀片铣削力数学模型及应力场有限元分析. 哈尔滨理工大学硕士论文.,2000
47 袁哲俊. 金属切削实验技术.机械工业出版社,1988: 26~64
48 王满元. 端面铣削的动态分析及减振机理. 哈尔滨工业出版社,1998
49 郑敏利, 李振加等. 三维复杂槽型铣刀片铣削力的数学模型. 制造技术与机床, 2000,417(5)
2 胡红兵. 1991-1995 年中国工具工业概况. 工具展望,1997,(1): 1~6
3 沈壮行. 工具工业面临的严重挑战和发展对策. 工具展望,1995,(4): 1~8
4 陈昆. 国内工具产品市场分析. 工具展望,1996,(3): 1~3
5 沈壮行. 中国工具工业的发展为什么赶不上制造业的需要——发展状况、问题浅谈和改进建议.机械工人, 2002,(9): 9~10
6 程伟. 切削加工和刀具技术的现状与发展. 工具展望, 2002,36(123): 3~6
7 M.Kronenberg.Initial Contact of Milling Cutter and Work-piece.MACHINERY, 1945:149~156
8 M.Kronenberg.Analysis of Initial contact of Milling Cutter and Work in Relation to Tool Life.ASME,1946:217~228
9 Opitz H,Beckhaus H.Influence of Initial Contact on Tool Life When Face Milling High Strength Materials. CIRP,1970 30(2):50~62
10 R. Werheim, A. Satron and A. Ber. Modifications of the Cutting Edge Geometry and Chip Formation in Milling. Annals of the CIRP,1994, 43(1): 63~68
11 The Association for Manufacturing Technology.IMTS96: What’s in the Mix for 96. Cutting Tool Engineering. 1996,48(5): 4~11
12 T. Hoshi. Development of High-performance Machining Technologies. International Conference on Machining Technology in Asian & Pacific Regions. Guangzhou,1993: 24~30
13 竹山秀彦,山田皓一.炭素钢 S50C の超硬正面フヲィス削リ.精密机械,1981,26(11):51~60
14 竹山,山田.合金钢 SNCM8(热处理)の超硬正面フヲィス削リ.精密机械,1983,29(6):83~102
15 竹山,山田.オ一ステナィナト不锈钢(SUS27)の超硬正面フヲィス削リ.精密机械,1982,30(2):65~90
16 于彦波等.硬质合金刀具断续切削破损理论. 华中理工大学出版社,1989,1~4
17 于彦波,王志勇.端铣刀切入破损机理的研究.哈尔滨科技大学学报,1987(3)
18 林树兴.面铣刀前刀面接触点计算的新方法.渝州大学学报,1995,12(1):26~31
19 张中民, 徐亦红, 李振加等. 圆形刀片切屑流向的试验研究[J]. 哈尔滨科学技术大学学报, 1996,20(2): 12~14
20 李振加,郑敏利,徐亦红,曲贵民.切屑折断过程研究[M]. 机械工业出版社, 1996
21 苏金明. MATLAB6.1 使用指南(下册)[M].电子工业出版社,2002
22 胡庆军,吴翊,李永乐. 应用数理统计.国防科技大学出版社[M], 2003
23 达世亮.汽车工业切削与刀具技术现状.工具技术,2004,38(9):38~42
24 赵炳桢.切削技术与刀具工业的新时代.工具技术,2004,38(9):24~26
25 井原透, 白坚高洋, 臼井英治. 断续切削における切れ刃欠损の解析的予测に关する研究(第 4 报). 精密机械.,1982,48(6): 71~77
26 N。Alfrli,The Efferfs of the Fracture Chipping and Wear of Cemented Carbide Tools on the Determination of the optimun Metal-Cutting Coneitions. Annals of the CIRP ,1981,30(1):68~81
27 刘战强,李兆前,艾兴.硬质合金刀具寿命分布规律的研究.硬质合金,1995,12(1):7~10
28 伊兵.粗加工模块式端铣刀及其破损机理的研究.哈尔滨科技大学硕士论文,1989
29 魏宗舒.概率论与数理统计教程.高等教育出版社,1999
30 姚英学,等.平头立铣刀铣削力模型中积分限的确定方法.工具技术,2004(38):11~13
31 李振加,等.波形刃铣刀片的开发及其铣削力数学模型[J].机械工程学报,2000,36(10):42-45
32 白新桂.数据分析与试验优化设计.清华大学出版社,1986
33 赵鸿.模块式重型车刀系统的研究.哈尔滨科技大学硕士论文.1988
34 B. Ghahramani, Z. Y.Wang, C. Sahay, K. P. Rajurkar. Analysis of Initial Contact and Tool Fracture in the Milling Process. Machining Science and Technology, 1999,3(1): 9~23
35 P. Lee, Y. Altintas. Prediction of Ball-end Milling Forces From Orthogonal Cutting Data. Int. J. Mach. Tools & Manufact., 1996,36(9): 1269~1290
36 H. Q. Zheng et al. Theoretical modeling and simulation of cutting forces in facemilling with cutter runout. Int. J. Mach. Tools & Manufact , 39(1999): 2003~2018
37 李振加,等.切屑空间运动轨迹及其约束方程的研究[J].机械工程学报,2001,37(12):42-46
38 李振加等. 铣削过程刀具破损原因的探讨. 机械工程学报,1993,29(4): 93~96
39 郑敏利. 模块式面铣刀合理几何参数实验研究. 哈尔滨电工学院学报.,1996,(2): 153~175
40 李振加等. 硬质合金刀具的粘结破损机理. 哈尔滨科学技术大学学报, 1993,17(3): 11~13
41 Fenglian, Sun. Adhering Wear Mechanism of Cemented Carbide Cutter in the Intervallic Cutting of Stainless Steel. Wear,1998,(214): 79~82
42 Zhenjia, Li. Waved-edge Insert Development and Milling Force Model. ICPCG’2000,2000
43 Zhenjia, Li. Milling Force Mode of Three-Dimensional Complex Groove Insert. IMCC’2000.,2000
44 Zhenjia, Li. Research on Sticking-welding Fracture Mechanism For cutter by Analyzing Three-Dimensional Stress Field. IMCC’95
45 Lihua, Dong. Study on Milling Properties of Three-Dimensional Complex Groove. 15th International Conference on Production Research Ireland,1999
46 陶海虹. 三维复杂槽型铣刀片铣削力数学模型及应力场有限元分析. 哈尔滨理工大学硕士论文.,2000
47 袁哲俊. 金属切削实验技术.机械工业出版社,1988: 26~64
48 王满元. 端面铣削的动态分析及减振机理. 哈尔滨工业出版社,1998
49 郑敏利, 李振加等. 三维复杂槽型铣刀片铣削力的数学模型. 制造技术与机床, 2000,417(5)