三维复杂槽型铣刀片切入破损理论及其应用技术研究
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摘要
重型机械、汽车、电站设备等是我国的支柱行业,其大型、复杂零部件的制造是企业生产的核心技术,大型、复杂零部件大多采用难加工材料,这些材料的特点是高硬度、高强度、高韧性,因此,加工时刀具破损严重,刀具使用寿命及生产效率很低。尤其是在FMS、CIMS等自动化生产中,刀具破损已成为关键技术及难题之一。经大量文献查询,以往有关切入破损机理研究都是针对平前刀面铣刀片进行的,对三维复杂槽型铣刀片切入破损机理研究很少有报道。近年来,三维复杂槽型铣刀片大量应用于机械加工的各个行业,但是理论研究严重落后于实际应用,三维复杂槽型铣刀片的应用和开发缺乏理论基础。
因此,本论文深入研究三维复杂槽型波形刃铣刀片的运动切入接触理论;推导三维复杂槽型波形刃铣刀片九种切入类型的判别数学模型;建立不同切入类型刀片的冲击破损寿命累积分布函数优选数学模型;进行三维复杂槽型波形刃铣刀片切入类型的仿真研究;通过优化开发出三维复杂槽型刀片和先进刀具产品,解决生产中刀具严重破损的问题。
基于模拟实验与数学分析,进行了三维复杂槽型波形刃铣刀片前刀面方程的推导、前刀面运动方程的推导、接触线方程的推导、交线方程的推导和切削域形貌方程的推导,从而形成三维复杂槽型波形刃铣刀片切入接触理论。
提出了三维复杂槽型波形刃铣刀片九种新的切入接触形式,引入前刀面接触角变化量δ,从而建立了三维复杂槽型波形刃铣刀片九种切入类型判别数学模型。
建立了不同切入类型刀片的三维复杂槽型波形刃铣刀片冲击破损寿命累积分布函数数学模型,得出刀片冲击破损寿命的概率分布服从威布尔概率分布函数的结论,优选出三维复杂槽型波形刃铣刀片切入破损类型,最佳的切入类型为U型,其余依次为V型、T型、S型。
进行了三维复杂槽型波形刃铣刀片切入类型的仿真研究。基于UG平台,利用UG提供的开发环境,结合UG/Open API及VC++编程软件,开发出三维复杂槽型波形刃铣刀片切入类型仿真系统,根据不同切入参数,采用实体建模技术,对三维复杂槽型波形刃铣刀片切入状态进行计算机模拟。
进行了三维复杂槽型刀片优化技术的研究。针对不同工件材料、刀具材料、加工条件、负载情况,采用实验室试验和现场试验相结合的方法,通过切入方式、切削力、切屑形状、切削寿命、失效形式、刀片材质等优化分析,建立三维复杂槽型铣刀片优化模型,优化切入方式、刀片槽型与几何参数以及刀片材质,开发出系列三维复杂槽型刀片。
The industry of the heavy machinery, automobiles and the power station equipment has become the pillar of our country. The manufacture of the huge and complex parts is the core technology of the manufactory. Most of their materials are difficult-to-cut materials. The characteristic of these materials is high in rigidity, strength and toughness. Therefore, the disrepair of the cutting tools is severe when machining. Both the cutting tools life is short and their efficiency of production is low. The disrepair of cutting tools is one of the key technigues and is a problem as well, particularly in automatization production of FMS、CIMS. Looking up a great deal of literature, the study of the cut-in disrepair is all about the flat-groove milling insert. And the study of mechanism of the cut-in disrepair for 3D complex groove milling insert seldom reported. In recent years, a great deal of 3D complex groove milling insert has been applied to the machining industry. But, the study of the theory is droped behind the practice. The theory base on the application and development of the 3D complex groove milling insert should be enhanced.
This paper described the moving contact theory of the 3D complex groove wave-edge milling insert. The mathematical model of nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is deduced. The excellent mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. The simulation system of waved-edge milling insert cut-in style is studied. The milling inserts and cutting tools with 3D complex groove are developed. Thus, the disrepair problems of cutters are solved.
Based on mathematical analysis and simulation experiment, the front face equation, the front face moving equation, the cut-in contact equation, the join line equation and the shape of cutting field equation for 3D complex groove wave-edge milling insert are deduceded. And the contact theory of 3D complex groove wave-edge milling insert is formed.
The nine new kinds of contact forms of the 3D complex groove wave-edge milling insert is put forward. The changing quantityδof contact angle of the front face is imported. Thereafter, the mathematical model of thr nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is established.
The mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. That conclusion of the cumulate function of impacting disrepair life obey to the function of Weibull is reached. The cut-in style of the 3D complex groove wave-edge milling insert is choosen for best. The excellent cut-in style is the U style, and the V style, T style and S style are followed in order.
The simulation system of waved-edge milling insert cut-in style is studied. Based on UG platform, under UG offered environment, with UG/Open API and VC++ software, the waved-edge milling insert cut-in simulation system is created. According to various parameters, by using modeling technology, the process of waved-edge milling insert cut-in can be simulated. The new method for studying 3D complex groove milling insert cut-in disrepair has been given.
Based on the mechanics and materials science, optimization technique of 3D complex groove wave-edge milling insert is studied. Various workpiece materials, cutter materials, processing conditions and loading, through experiment both in laboratories and in factorier, by analyzing cutting force, chip shape, cutting life, failure form and insert material, optimization model of stress field for 3D complex groove milling insert is developed. The insert groove and geometric parameters, together with material are optimized. The series of 3D complex groove milling insert are developed.
因此,本论文深入研究三维复杂槽型波形刃铣刀片的运动切入接触理论;推导三维复杂槽型波形刃铣刀片九种切入类型的判别数学模型;建立不同切入类型刀片的冲击破损寿命累积分布函数优选数学模型;进行三维复杂槽型波形刃铣刀片切入类型的仿真研究;通过优化开发出三维复杂槽型刀片和先进刀具产品,解决生产中刀具严重破损的问题。
基于模拟实验与数学分析,进行了三维复杂槽型波形刃铣刀片前刀面方程的推导、前刀面运动方程的推导、接触线方程的推导、交线方程的推导和切削域形貌方程的推导,从而形成三维复杂槽型波形刃铣刀片切入接触理论。
提出了三维复杂槽型波形刃铣刀片九种新的切入接触形式,引入前刀面接触角变化量δ,从而建立了三维复杂槽型波形刃铣刀片九种切入类型判别数学模型。
建立了不同切入类型刀片的三维复杂槽型波形刃铣刀片冲击破损寿命累积分布函数数学模型,得出刀片冲击破损寿命的概率分布服从威布尔概率分布函数的结论,优选出三维复杂槽型波形刃铣刀片切入破损类型,最佳的切入类型为U型,其余依次为V型、T型、S型。
进行了三维复杂槽型波形刃铣刀片切入类型的仿真研究。基于UG平台,利用UG提供的开发环境,结合UG/Open API及VC++编程软件,开发出三维复杂槽型波形刃铣刀片切入类型仿真系统,根据不同切入参数,采用实体建模技术,对三维复杂槽型波形刃铣刀片切入状态进行计算机模拟。
进行了三维复杂槽型刀片优化技术的研究。针对不同工件材料、刀具材料、加工条件、负载情况,采用实验室试验和现场试验相结合的方法,通过切入方式、切削力、切屑形状、切削寿命、失效形式、刀片材质等优化分析,建立三维复杂槽型铣刀片优化模型,优化切入方式、刀片槽型与几何参数以及刀片材质,开发出系列三维复杂槽型刀片。
The industry of the heavy machinery, automobiles and the power station equipment has become the pillar of our country. The manufacture of the huge and complex parts is the core technology of the manufactory. Most of their materials are difficult-to-cut materials. The characteristic of these materials is high in rigidity, strength and toughness. Therefore, the disrepair of the cutting tools is severe when machining. Both the cutting tools life is short and their efficiency of production is low. The disrepair of cutting tools is one of the key technigues and is a problem as well, particularly in automatization production of FMS、CIMS. Looking up a great deal of literature, the study of the cut-in disrepair is all about the flat-groove milling insert. And the study of mechanism of the cut-in disrepair for 3D complex groove milling insert seldom reported. In recent years, a great deal of 3D complex groove milling insert has been applied to the machining industry. But, the study of the theory is droped behind the practice. The theory base on the application and development of the 3D complex groove milling insert should be enhanced.
This paper described the moving contact theory of the 3D complex groove wave-edge milling insert. The mathematical model of nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is deduced. The excellent mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. The simulation system of waved-edge milling insert cut-in style is studied. The milling inserts and cutting tools with 3D complex groove are developed. Thus, the disrepair problems of cutters are solved.
Based on mathematical analysis and simulation experiment, the front face equation, the front face moving equation, the cut-in contact equation, the join line equation and the shape of cutting field equation for 3D complex groove wave-edge milling insert are deduceded. And the contact theory of 3D complex groove wave-edge milling insert is formed.
The nine new kinds of contact forms of the 3D complex groove wave-edge milling insert is put forward. The changing quantityδof contact angle of the front face is imported. Thereafter, the mathematical model of thr nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is established.
The mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. That conclusion of the cumulate function of impacting disrepair life obey to the function of Weibull is reached. The cut-in style of the 3D complex groove wave-edge milling insert is choosen for best. The excellent cut-in style is the U style, and the V style, T style and S style are followed in order.
The simulation system of waved-edge milling insert cut-in style is studied. Based on UG platform, under UG offered environment, with UG/Open API and VC++ software, the waved-edge milling insert cut-in simulation system is created. According to various parameters, by using modeling technology, the process of waved-edge milling insert cut-in can be simulated. The new method for studying 3D complex groove milling insert cut-in disrepair has been given.
Based on the mechanics and materials science, optimization technique of 3D complex groove wave-edge milling insert is studied. Various workpiece materials, cutter materials, processing conditions and loading, through experiment both in laboratories and in factorier, by analyzing cutting force, chip shape, cutting life, failure form and insert material, optimization model of stress field for 3D complex groove milling insert is developed. The insert groove and geometric parameters, together with material are optimized. The series of 3D complex groove milling insert are developed.
引文
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