可转位铣刀片温度场、应力场分析及槽型重构研究
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摘要
论文主要针对可转位铣刀片的温度场和应力场进行了理论分析和实验研究。在对可转位铣刀片温度场和应力场试验研究的基础上,进行有限元分析及耦合场分析,并针对铣刀片温度场和应力场的非稳态特性,开发了波形刃铣刀片模糊综合评判系统,基于温度场分析和温度场的评价准则进行槽型重构。
本课题来源于国家自然科学基金项目“三维复杂槽型车铣刀片自组织优化设计的研究”。在综述了刀具技术的发展现状和国内外铣刀片的发展概况基础上,对有关铣刀片的铣削机理、刀具开发设计技术和槽型CAD/CAM技术的文献进行了系统全面的综述。
论文首先对可转位铣刀片温度场、应力场进行了试验研究。利用动态数据采集系统对平前刀面铣刀片和波形刃铣刀片的铣削温度和铣削力同时进行了测量,得到了铣刀片各个测温点的温度以及前刀面刀-屑接触区的平均温度与时间之间的试验方程式,利用MATLAB软件,对采集到的力进行数据拟合,得到了波形刃铣刀片和平前刀面铣刀片X、Y、Z三向铣削力与时间之间的试验方程式。从试验角度比较出了两种槽型铣刀铣削温度和铣削力的大小。所得到的温度与力对时间的方程式,为铣刀片受热密度函数、受力密度函数的建立,为温度场和应力场有限元分析打下了基础。
其次对可转位铣刀片温度场、应力场有限元分析及耦合进行了研究。基于传热学理论,利用热源法建立了铣刀片受热密度函数,可以得到任意槽型参数已知的铣刀片受热密度函数的模型和表面受热密度函数。对铣刀片的实体模型进行有限元网格划分,确定温度场分析的边界条件,对温度场进行了有限元分析。对五种不同槽型的铣刀片进行了不同切削参数的试验,建立了平前刀面铣刀片和波形刃铣刀片的表面受力密度函数。给出了波形刃铣刀片波形参数设计思想和受力密度函数的曲线及曲面模拟。选取切削过程中的任意时刻进行了应力场有限元分析,得到了波形刃铣刀片和平前刀面铣刀片的应力分布规律和受力变形情况,利用有限元分析软件ANSYS的多场耦合的分析功能,把温度场的分析结果作为体载荷,分别对波形刃铣刀片和平前刀面铣刀片进行了热应力分析,得出了两种铣刀片热应力和位移的分布规律。在热应力计算结果基础上,进一步对热应力与机械应力进行了耦合分析,得出了温度场与应力场耦合后的综合结果。通过对平前刀面铣刀片和波形刃铣刀片热力耦合物理场有限元计算结果与试验结果的对比,从耦合场层面上说明了带有槽型刀具切削性能的优越性。
再次对可转位铣刀片温度场、应力场预测及模糊评判进行了研究。针对铣刀片温度场和应力场的非稳态特性,基于人工神经网络理论,采用BP神经网络Levenberg-Marquardt算法建立了三维复杂槽型铣刀片温度场和应力场预测模型,运用模糊数学理论,根据加工要求和专家分析,在VC++环境下,实现了对波形刃铣刀片模糊综合评判系统的开发。通过该系统可对多因素作用下的铣刀片温度场、应力场和耦合场的优劣进行评判,为铣刀片槽型参数的优化提供了评判依据。
最后完成了可转位铣刀片的槽型重构设计。主要是基于温度场分析和温度场的评价准则进行槽型重构。建立槽型参数多目标优化数学模型,利用遗传算法求解了固定切削参数和给定约束下的优化槽型参数,槽型优化后的铣刀片耦合场明显优于其它槽型参数下的铣刀片耦合场。在Pro/E环境下,创建了波形刃铣刀片模型,利用Pro/TOOLKIT二次开发工具,采用异步模式完成了槽型参数化重构系统的开发,实现了利用友好的图形用户界面输入槽型设计参数来控制铣刀片复杂槽型生成的关键技术。
Theory analysis and experiment study of temperature field and stress field of turnable milling insert are mainly completed in the paper. On the basis of experiment study of temperature field and stress field of turnable milling insert, finite element analysis and coupling field analysis are implemented. In terms of unstable characteristics of temperature field and stress field of turnable milling insert a fuzzy synthesis judge system of wave edge milling insert is developed. Groove reconstruction is carried out based on temperature field analysis and temperature field evaluation guidelines.
The research work comes from a project funded by NSFC (National Natural Science Foundation of China), which is "The research on self organization optimize design of milling insert with 3DM complex groove". After development status of tool technology and evolution survey of milling insert over the world, and still overview milling mechanism of milling insert, tool development and design technology and groove CAD/CAM technology.
Firstly the experiment study of temperature field and stress field of turnable milling insert is implemented. Milling temperature and milling force of smooth front and wave edge milling insert is synchronously measured by applying dynamic data acquisition system. The temperature values of every measured point on milling insert are acquired and still experiment equation between average temperature of edge-chip contact area in front tool surface and time. The value collected carry through data fitting by MATLAB software and the experiment equations of X, Y, Z three directions milling forces and time for wave edge and smooth edge milling insert are obtained. From the experiment we compare milling temperature and milling force of two kinds of grooves milling. The equations gained between temperature and force and time are foundation for deriving heated density function, force density function and the finite element analyses of temperature field and stress field.
Secondly the finite element analysis and coupling field of temperature field and stress field of turnable milling insert is studied. Based on heat transfer theory heated density function of milling insert is built up by using heat source method. So heated density function model and surface heated density function are gained when any groove parameters known of milling insert. The solid model of milling insert is meshed finite element and the boundary condition of temperature field is determined. The finite element analysis of temperature field is carried out. The experiments of milling insert with five sorts groove is completed when cutting parameters are different. The surface force density functions are set up for smooth front edge and wave edge milling insert. The wave parameters design concept of wave edge milling insert and curve and curved surface fitting of force density function are given. The finite element analysis of stress field in any the time during cutting process is implemented. The stress distribution rule and distortion of wave edge and smooth front edge milling are got. By multi-coupling field analysis function of finite element analysis software ANSYS heat stress analysis of wave edge and smooth front edge milling are given for the analysis results of temperature field as body load. The distribution rule of heat stress and displacement are obtained. On the basis of heat stress calculation the coupling between heat stress and mechanical stress is analyzed. We gain synthesis result of temperature field and stress field coupling each other. By comparing the finite element calculation results to experiment results of heat and force coupling physics field of smooth front edge and wave edge milling, cutting capability suoeriority of milling with groove is explained from coupling field.
Thirdly the forecast and fuzzy judgement of temperature field and stress field of turnable milling is studied. According to nonstable performances of temperature field and stress field of milling, based on man nerve network thoery the forecast model of emperature field and stress field milling with 3DM complex groove is established by using Levenberg-Marquardt algorithm of BP nerve network. By employing fuzzy mathematics theory, in terms of machining requirements and specialist analysis fuzzy synthesis judgement system for wave edge milling is developed in VC++ environment. By using the system qualities of temperature field, stress field and coupling field in multiple factors action judged. It provides evaluation basis for optimization of milling groove parameters.
Lastly groove reconstruction design of turnable milling insert is carried out. The groove reconstruction is mainly based on temperature field analysis and temperiture field judgement guideline. Multiple object optimization mathematical model of groove parameters is set up. Applying genetics algorithm solves optimizing groove parameters of changeless cutting parameters and given constraint. The milling coupling field after groove optimizing has markedly superiority over others. In Pro/E environment the solid model of wave edge milling insert is found. By using Pro/TOOLKIT secondary exploitation tool, groove parameters reconstruction system is developed by employing asynchronism mode. The key technology is fulfill by using friendly graph user interface inputs groove design parameters to control complex groove generation of milling insert.
本课题来源于国家自然科学基金项目“三维复杂槽型车铣刀片自组织优化设计的研究”。在综述了刀具技术的发展现状和国内外铣刀片的发展概况基础上,对有关铣刀片的铣削机理、刀具开发设计技术和槽型CAD/CAM技术的文献进行了系统全面的综述。
论文首先对可转位铣刀片温度场、应力场进行了试验研究。利用动态数据采集系统对平前刀面铣刀片和波形刃铣刀片的铣削温度和铣削力同时进行了测量,得到了铣刀片各个测温点的温度以及前刀面刀-屑接触区的平均温度与时间之间的试验方程式,利用MATLAB软件,对采集到的力进行数据拟合,得到了波形刃铣刀片和平前刀面铣刀片X、Y、Z三向铣削力与时间之间的试验方程式。从试验角度比较出了两种槽型铣刀铣削温度和铣削力的大小。所得到的温度与力对时间的方程式,为铣刀片受热密度函数、受力密度函数的建立,为温度场和应力场有限元分析打下了基础。
其次对可转位铣刀片温度场、应力场有限元分析及耦合进行了研究。基于传热学理论,利用热源法建立了铣刀片受热密度函数,可以得到任意槽型参数已知的铣刀片受热密度函数的模型和表面受热密度函数。对铣刀片的实体模型进行有限元网格划分,确定温度场分析的边界条件,对温度场进行了有限元分析。对五种不同槽型的铣刀片进行了不同切削参数的试验,建立了平前刀面铣刀片和波形刃铣刀片的表面受力密度函数。给出了波形刃铣刀片波形参数设计思想和受力密度函数的曲线及曲面模拟。选取切削过程中的任意时刻进行了应力场有限元分析,得到了波形刃铣刀片和平前刀面铣刀片的应力分布规律和受力变形情况,利用有限元分析软件ANSYS的多场耦合的分析功能,把温度场的分析结果作为体载荷,分别对波形刃铣刀片和平前刀面铣刀片进行了热应力分析,得出了两种铣刀片热应力和位移的分布规律。在热应力计算结果基础上,进一步对热应力与机械应力进行了耦合分析,得出了温度场与应力场耦合后的综合结果。通过对平前刀面铣刀片和波形刃铣刀片热力耦合物理场有限元计算结果与试验结果的对比,从耦合场层面上说明了带有槽型刀具切削性能的优越性。
再次对可转位铣刀片温度场、应力场预测及模糊评判进行了研究。针对铣刀片温度场和应力场的非稳态特性,基于人工神经网络理论,采用BP神经网络Levenberg-Marquardt算法建立了三维复杂槽型铣刀片温度场和应力场预测模型,运用模糊数学理论,根据加工要求和专家分析,在VC++环境下,实现了对波形刃铣刀片模糊综合评判系统的开发。通过该系统可对多因素作用下的铣刀片温度场、应力场和耦合场的优劣进行评判,为铣刀片槽型参数的优化提供了评判依据。
最后完成了可转位铣刀片的槽型重构设计。主要是基于温度场分析和温度场的评价准则进行槽型重构。建立槽型参数多目标优化数学模型,利用遗传算法求解了固定切削参数和给定约束下的优化槽型参数,槽型优化后的铣刀片耦合场明显优于其它槽型参数下的铣刀片耦合场。在Pro/E环境下,创建了波形刃铣刀片模型,利用Pro/TOOLKIT二次开发工具,采用异步模式完成了槽型参数化重构系统的开发,实现了利用友好的图形用户界面输入槽型设计参数来控制铣刀片复杂槽型生成的关键技术。
Theory analysis and experiment study of temperature field and stress field of turnable milling insert are mainly completed in the paper. On the basis of experiment study of temperature field and stress field of turnable milling insert, finite element analysis and coupling field analysis are implemented. In terms of unstable characteristics of temperature field and stress field of turnable milling insert a fuzzy synthesis judge system of wave edge milling insert is developed. Groove reconstruction is carried out based on temperature field analysis and temperature field evaluation guidelines.
The research work comes from a project funded by NSFC (National Natural Science Foundation of China), which is "The research on self organization optimize design of milling insert with 3DM complex groove". After development status of tool technology and evolution survey of milling insert over the world, and still overview milling mechanism of milling insert, tool development and design technology and groove CAD/CAM technology.
Firstly the experiment study of temperature field and stress field of turnable milling insert is implemented. Milling temperature and milling force of smooth front and wave edge milling insert is synchronously measured by applying dynamic data acquisition system. The temperature values of every measured point on milling insert are acquired and still experiment equation between average temperature of edge-chip contact area in front tool surface and time. The value collected carry through data fitting by MATLAB software and the experiment equations of X, Y, Z three directions milling forces and time for wave edge and smooth edge milling insert are obtained. From the experiment we compare milling temperature and milling force of two kinds of grooves milling. The equations gained between temperature and force and time are foundation for deriving heated density function, force density function and the finite element analyses of temperature field and stress field.
Secondly the finite element analysis and coupling field of temperature field and stress field of turnable milling insert is studied. Based on heat transfer theory heated density function of milling insert is built up by using heat source method. So heated density function model and surface heated density function are gained when any groove parameters known of milling insert. The solid model of milling insert is meshed finite element and the boundary condition of temperature field is determined. The finite element analysis of temperature field is carried out. The experiments of milling insert with five sorts groove is completed when cutting parameters are different. The surface force density functions are set up for smooth front edge and wave edge milling insert. The wave parameters design concept of wave edge milling insert and curve and curved surface fitting of force density function are given. The finite element analysis of stress field in any the time during cutting process is implemented. The stress distribution rule and distortion of wave edge and smooth front edge milling are got. By multi-coupling field analysis function of finite element analysis software ANSYS heat stress analysis of wave edge and smooth front edge milling are given for the analysis results of temperature field as body load. The distribution rule of heat stress and displacement are obtained. On the basis of heat stress calculation the coupling between heat stress and mechanical stress is analyzed. We gain synthesis result of temperature field and stress field coupling each other. By comparing the finite element calculation results to experiment results of heat and force coupling physics field of smooth front edge and wave edge milling, cutting capability suoeriority of milling with groove is explained from coupling field.
Thirdly the forecast and fuzzy judgement of temperature field and stress field of turnable milling is studied. According to nonstable performances of temperature field and stress field of milling, based on man nerve network thoery the forecast model of emperature field and stress field milling with 3DM complex groove is established by using Levenberg-Marquardt algorithm of BP nerve network. By employing fuzzy mathematics theory, in terms of machining requirements and specialist analysis fuzzy synthesis judgement system for wave edge milling is developed in VC++ environment. By using the system qualities of temperature field, stress field and coupling field in multiple factors action judged. It provides evaluation basis for optimization of milling groove parameters.
Lastly groove reconstruction design of turnable milling insert is carried out. The groove reconstruction is mainly based on temperature field analysis and temperiture field judgement guideline. Multiple object optimization mathematical model of groove parameters is set up. Applying genetics algorithm solves optimizing groove parameters of changeless cutting parameters and given constraint. The milling coupling field after groove optimizing has markedly superiority over others. In Pro/E environment the solid model of wave edge milling insert is found. By using Pro/TOOLKIT secondary exploitation tool, groove parameters reconstruction system is developed by employing asynchronism mode. The key technology is fulfill by using friendly graph user interface inputs groove design parameters to control complex groove generation of milling insert.
引文
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