金属切削过程仿真及其在断屑槽性能研究中的应用
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摘要
本文在研究了金属切削原理和有限元理论的基础上，借鉴前人在二维切削仿真研究中的成果与结论，选择了基于等效塑性应变的切屑分离准则，建立了有限元分析模型，利用商业化的有限元分析软件进行了求解运算，动态模拟了三维状态的金属切削过程。本文具体研究内容如下：
1、建立了二维切削加工有限元分析模型，进行了仿真实验。对金属切削过程中应力场、应变场的变化及其规律作了定性分析。给出了应力、应变等值线图，观察了切削过程中各主要变形区位置和剪切带形成过程。仿真结果验证了随刀具前角增大，剪切角相应增大。
2、建立了斜角切削加工有限元分析模型，进行了仿真实验。通过提取切屑模型的关键线进行测量，得到了切削过程中切屑流屑角、上卷半径和侧卷半径的数值；验证了流屑角和刀具刃倾角总是近似相等的斯坦布勒实验法则；并实现了利用有限元仿真对切屑形态与受阻运动趋势的预测。
3、建立了三维切削加工有限元分析模型，进行了仿真实验。研究了切削力变化规律和切屑成形过程。仿真得到了不同切削用量下的切削力数值，为切削工艺研究及刀具设计提供了有用数据。通过和切削试验结果进行对比分析，验证了仿真结果的准确性，证明了仿真模型的有效性。
4、为了将该仿真模型应用于刀具断屑槽形的设计与优化，本文通过改变全圆弧槽形刀具几何参数进行了一系列仿真实验，完成了对该种槽形流屑、卷屑性能的定性研究，得到了一些有意义的结论。
5、开发了金属切削过程仿真分析的集成软件。工艺人员通过软件友好的人机界面，可以完成相应条件下的程序编写，计算分析，数据处理及结果演示。软件操作方便，运行可靠。
A Lagrangian finite element model of three dimensional machining is developed to simulate the metal cutting process in this thesis, among which a chip-separation criterion based on the failure character of the material model is the most important. The simulation is performed with a general international finite element-based modeling software. The main work in this thesis can be concluded as follows.
1 .The orthogonal cutting model is validated against the state of stress and strain, the form of shear plane and the effect of the tool rake angle on the angle of shear plane.
2.The obique cutting model is validated against the relation between the chip flow angle and the tool inclination angle, upward chip curling and sideward chip curling. Therefore, the geometric shapes and the movement of the chip can be predicted accurately.
3.The three dimensional cutting model is validated against predictions of cutting forces and chip formation under several cutting conditions. Comparisons of predictions are made against test data to further verify the feasibility of the model.
4.1n order to design and optimize the geometry parameters of the chip breaker, some cutting simulations under a variety of parameters are carried through to investigate the effect of the breaker on the geometric shapes of the chip.
5.The integrated software is developed to analyze the cutting forces and chip formation. Using the software, the simulation programs are automatically set up, and the cutting forces and chip formation under different machining conditions can be computed expediently.
1、建立了二维切削加工有限元分析模型，进行了仿真实验。对金属切削过程中应力场、应变场的变化及其规律作了定性分析。给出了应力、应变等值线图，观察了切削过程中各主要变形区位置和剪切带形成过程。仿真结果验证了随刀具前角增大，剪切角相应增大。
2、建立了斜角切削加工有限元分析模型，进行了仿真实验。通过提取切屑模型的关键线进行测量，得到了切削过程中切屑流屑角、上卷半径和侧卷半径的数值；验证了流屑角和刀具刃倾角总是近似相等的斯坦布勒实验法则；并实现了利用有限元仿真对切屑形态与受阻运动趋势的预测。
3、建立了三维切削加工有限元分析模型，进行了仿真实验。研究了切削力变化规律和切屑成形过程。仿真得到了不同切削用量下的切削力数值，为切削工艺研究及刀具设计提供了有用数据。通过和切削试验结果进行对比分析，验证了仿真结果的准确性，证明了仿真模型的有效性。
4、为了将该仿真模型应用于刀具断屑槽形的设计与优化，本文通过改变全圆弧槽形刀具几何参数进行了一系列仿真实验，完成了对该种槽形流屑、卷屑性能的定性研究，得到了一些有意义的结论。
5、开发了金属切削过程仿真分析的集成软件。工艺人员通过软件友好的人机界面，可以完成相应条件下的程序编写，计算分析，数据处理及结果演示。软件操作方便，运行可靠。
A Lagrangian finite element model of three dimensional machining is developed to simulate the metal cutting process in this thesis, among which a chip-separation criterion based on the failure character of the material model is the most important. The simulation is performed with a general international finite element-based modeling software. The main work in this thesis can be concluded as follows.
1 .The orthogonal cutting model is validated against the state of stress and strain, the form of shear plane and the effect of the tool rake angle on the angle of shear plane.
2.The obique cutting model is validated against the relation between the chip flow angle and the tool inclination angle, upward chip curling and sideward chip curling. Therefore, the geometric shapes and the movement of the chip can be predicted accurately.
3.The three dimensional cutting model is validated against predictions of cutting forces and chip formation under several cutting conditions. Comparisons of predictions are made against test data to further verify the feasibility of the model.
4.1n order to design and optimize the geometry parameters of the chip breaker, some cutting simulations under a variety of parameters are carried through to investigate the effect of the breaker on the geometric shapes of the chip.
5.The integrated software is developed to analyze the cutting forces and chip formation. Using the software, the simulation programs are automatically set up, and the cutting forces and chip formation under different machining conditions can be computed expediently.
引文
1．肖诗纲编著．现代刀具材料．重庆：重庆大学出版社，1992．2
2．陈永洁，师汉民等．三维断屑槽的作用机理．湖北工学院学报，1994，9(3)：160～164
3．何腾芸，于启勋等．断屑机理和断屑判据．哈尔滨科学技术大学学报，1989．4
4．吴新凉，陈永洁，彭冰．复合断屑槽型结构及双槽刀片断屑性能试验研究．机械工程师，1999，1：40～42
5．(苏)罗金著，喻怀仁，陈世忠等译．金属切削刀具．北京：机械工业出版社，1985．8
6．(美)G．E．凯恩编，赵广兴，陆贲译．切削刀具新的发展方向．北京：机械工业出版社，1987．10
7．张幼桢主编．金属切削理论．北京：航空工业出版社，1988．6
8．陈永洁，王振岭，陆涛等．基于人工神经网络的可转位刀片3维断屑槽的建模和预测．制造业自动化，2000，22(5)：24～26
9．王冒成，邵敏编著．有限单元法基本原理和数值方法．北京：清华大学出版社，1996
10. Fang Ning. Kinematic Characterization of Chip Lateral-Curl—The Third Pattem of Chip Curl in Machining. Journal of Manufacturing Science andEngineering,124(2002):667～675
11．施志辉，赵玢，王启义等．金属切削加工切屑形成过程仿真技术．大连铁道学院学报，2000，21(3)：64～68
12．蒋孝煜编著．有限元法基础．北京：清华大学出版社，1992
13．王秉愚著．有限元法程序设计．北京：北京理工大学出版社，1991．12
14．谭建国编著．使用ANSYS6.0进行有限元分析．北京：北京大学出版社．2002．5
15. Marusich T D , Ortiz M . Modeling and Simulation of High-Speed Machining.International Journal for Numerical Methods in Engineering,38(1995):3675～3694
16. Kalhori V , Lundblad M,Lindgren L E. Numerical and Experimental Analysis of Orthogonal Metal Cutting. ASME 1997 International Mechanical Engineering Congress & Exposition, MED Vol.6-2
17. Komvopoulos K ,Erpenbeck S A. Finite Element Modeling of Orthogonal Metal Cutting. Journal of Engineering Industry, 113(1991):253～267
18. Strenkowski J S , Athavale S M . A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tool . Journal of Manufacturing Science, 119(1997):681～688
19. Mov.ahhedy M R, Altintas Y, Gadala M S. Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools. Journal of Manufacturing Science and
Engineering．124(2002)：178～188
20．张幼桢主编．金属切削原理及刀具．航空专业教材编审组，1989
21．刘晓玉，明冬兰，吴斌等．大刃倾角斜角切削流屑角的实验研究．机械设计与制造，1999，12：37～39
22．朱伯芳编著．有限单元法原理与应用．北京：中国水利水电出版社，1998．10
23．李人宪编著．有限元法基础．北京：国防工业出版社，2002．5
24. Livermore Software Technology Corporation. LS-DYNA Theoretical Manual.Livermore Software Technology Corporation,1998.5
25．朱利华，胡忠，王本一等．基于有限变形理论的二维热弹塑性有限元模拟技术的研究。机械工程学报，1999，35(3)：108～112
26. Weber G G , Lush A M, Zavaliangos A, et al. An objective time-integration procedure for isotropic rate-independent and rate-dependent elastic-plastic constitutive equations. International Journal of Plasticity,1990,6:701～744
27．K．J．巴特，E．L．威尔逊著．有限元分析中的数值方法．北京：科学出版社，1985．5
28. ANSYS Inc.ANSYS Theory Manual(Revision 5.7).ANSYS Inc,2001.3
29. Livermore Software Technology Corporation. LS-DYNA Keyword User's Manual(Version 960).Livermore Software Technology Corporation,2001.3
30. ANSYS Inc.ANSYS/LS-DYNA User's Guide.ANSYS Inc,2001.3
31. Martin Baker, Joachim Rosier, Carsten Siemens. Finite Element Simulation of Segmented Chip Formation of Ti6A14V. Journal of Manufacturing Science and Engineering, 124(2002):485～488
32．黄志刚，柯映林，王立涛．金属切削加工有限元模拟的相关技术研究．中国机械工程，2003，14(10)：846～849
33. Sasahara H,Obikawa T ,Shirakashi T. FEM Analysis of Cutting Sequence Effect on Mechanical Characteristics in Machined Layer.Journal of Materials Processing Technology,62(1996):448～453
34. Zone-Ching Lin, Yeou-yih Lin . A Study of an Oblique Cutting Model.Journal of Materials Processing Technology, 1999,86:119～130
35. Arola D, Sultan M B, Ramulu M. Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics. Journal of Manufacturing Science and Engineering,2002,124:32～41
36. Strebjiwsjum H S,Carroll J T.A finite element model of orthogonal metal cutting.In: Proceedings of the North American Manufacturing Research Conference,Bethlehem,Pennsylvania, 1987,506～509
37. Zone-Ching Lin, Wun-Ling Lai, H Y Lin et al. The study of ultra-precision machining and residual stress for NiP alloy with different cuttingspeeds and
depth of cut. Journal of Materials Processing Technology,2000,97:200～210
38．方刚，曾攀．切削加工过程数值模拟的研究进展．力学进展，2001，31(3)：394～404
39．方刚，雷丽萍，曾攀．金属塑性成形过程延性断裂的准则及其数值模拟．机械工程学报，2002，38(增刊)：21～25
40．郑长卿，周利，张克实著．金属韧性破坏的细观力学及其应用研究．北京：国防工业出版社，1995．9
41. Ritchie R O, Thompson A W . On Macroscopic and Microscopic Analyses for Crack Initiation and Crack Growth Toughness in Ductile Alloys. Metall. Trans.,16A(1985):233～247
42. ANSYS Inc.ANSYS 6.0 APDL Programmer's Guide.ANSYS Inc,2001.3
43．陈精一，蔡忠国编著．电脑辅助工程分析：ANSYS使用指南．北京：中国铁道出版社，2001．4
44．《机械工程材料性能数据手册》编委会编．机械工程材料性能数据手册．北京：机械工业出版社，1994．12
45．赵吉文．二维金属切削过程计算机仿真及刀具几何参数优化．合肥工业大学，2002
46．嘉木工作室编著．UG18实体建模实例教程．北京：机械工业出版社，2002．5
47．清宏计算机工作室编著．Delphi编程技巧．北京：机械工业出版社，2001．1
48．韩伟峰编著．Delphi6程序设计教程．北京：清华大学出版社，2002．1
49. van Luttervelt C A , Childs T H C ed. Present situation and future trendsin modeling of machining operations. Keynote Paper. Annual of the CIRP,1998,47(2):587～626
50. Fang N, Jawahir IS. Analytical Prediction of the Chip Back-Flow Anglein Machining With Restricted Contact Grooved Tools.Journal of Manufacturing and Engineering,125(2003):210～219
2．陈永洁，师汉民等．三维断屑槽的作用机理．湖北工学院学报，1994，9(3)：160～164
3．何腾芸，于启勋等．断屑机理和断屑判据．哈尔滨科学技术大学学报，1989．4
4．吴新凉，陈永洁，彭冰．复合断屑槽型结构及双槽刀片断屑性能试验研究．机械工程师，1999，1：40～42
5．(苏)罗金著，喻怀仁，陈世忠等译．金属切削刀具．北京：机械工业出版社，1985．8
6．(美)G．E．凯恩编，赵广兴，陆贲译．切削刀具新的发展方向．北京：机械工业出版社，1987．10
7．张幼桢主编．金属切削理论．北京：航空工业出版社，1988．6
8．陈永洁，王振岭，陆涛等．基于人工神经网络的可转位刀片3维断屑槽的建模和预测．制造业自动化，2000，22(5)：24～26
9．王冒成，邵敏编著．有限单元法基本原理和数值方法．北京：清华大学出版社，1996
10. Fang Ning. Kinematic Characterization of Chip Lateral-Curl—The Third Pattem of Chip Curl in Machining. Journal of Manufacturing Science andEngineering,124(2002):667～675
11．施志辉，赵玢，王启义等．金属切削加工切屑形成过程仿真技术．大连铁道学院学报，2000，21(3)：64～68
12．蒋孝煜编著．有限元法基础．北京：清华大学出版社，1992
13．王秉愚著．有限元法程序设计．北京：北京理工大学出版社，1991．12
14．谭建国编著．使用ANSYS6.0进行有限元分析．北京：北京大学出版社．2002．5
15. Marusich T D , Ortiz M . Modeling and Simulation of High-Speed Machining.International Journal for Numerical Methods in Engineering,38(1995):3675～3694
16. Kalhori V , Lundblad M,Lindgren L E. Numerical and Experimental Analysis of Orthogonal Metal Cutting. ASME 1997 International Mechanical Engineering Congress & Exposition, MED Vol.6-2
17. Komvopoulos K ,Erpenbeck S A. Finite Element Modeling of Orthogonal Metal Cutting. Journal of Engineering Industry, 113(1991):253～267
18. Strenkowski J S , Athavale S M . A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tool . Journal of Manufacturing Science, 119(1997):681～688
19. Mov.ahhedy M R, Altintas Y, Gadala M S. Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools. Journal of Manufacturing Science and
Engineering．124(2002)：178～188
20．张幼桢主编．金属切削原理及刀具．航空专业教材编审组，1989
21．刘晓玉，明冬兰，吴斌等．大刃倾角斜角切削流屑角的实验研究．机械设计与制造，1999，12：37～39
22．朱伯芳编著．有限单元法原理与应用．北京：中国水利水电出版社，1998．10
23．李人宪编著．有限元法基础．北京：国防工业出版社，2002．5
24. Livermore Software Technology Corporation. LS-DYNA Theoretical Manual.Livermore Software Technology Corporation,1998.5
25．朱利华，胡忠，王本一等．基于有限变形理论的二维热弹塑性有限元模拟技术的研究。机械工程学报，1999，35(3)：108～112
26. Weber G G , Lush A M, Zavaliangos A, et al. An objective time-integration procedure for isotropic rate-independent and rate-dependent elastic-plastic constitutive equations. International Journal of Plasticity,1990,6:701～744
27．K．J．巴特，E．L．威尔逊著．有限元分析中的数值方法．北京：科学出版社，1985．5
28. ANSYS Inc.ANSYS Theory Manual(Revision 5.7).ANSYS Inc,2001.3
29. Livermore Software Technology Corporation. LS-DYNA Keyword User's Manual(Version 960).Livermore Software Technology Corporation,2001.3
30. ANSYS Inc.ANSYS/LS-DYNA User's Guide.ANSYS Inc,2001.3
31. Martin Baker, Joachim Rosier, Carsten Siemens. Finite Element Simulation of Segmented Chip Formation of Ti6A14V. Journal of Manufacturing Science and Engineering, 124(2002):485～488
32．黄志刚，柯映林，王立涛．金属切削加工有限元模拟的相关技术研究．中国机械工程，2003，14(10)：846～849
33. Sasahara H,Obikawa T ,Shirakashi T. FEM Analysis of Cutting Sequence Effect on Mechanical Characteristics in Machined Layer.Journal of Materials Processing Technology,62(1996):448～453
34. Zone-Ching Lin, Yeou-yih Lin . A Study of an Oblique Cutting Model.Journal of Materials Processing Technology, 1999,86:119～130
35. Arola D, Sultan M B, Ramulu M. Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics. Journal of Manufacturing Science and Engineering,2002,124:32～41
36. Strebjiwsjum H S,Carroll J T.A finite element model of orthogonal metal cutting.In: Proceedings of the North American Manufacturing Research Conference,Bethlehem,Pennsylvania, 1987,506～509
37. Zone-Ching Lin, Wun-Ling Lai, H Y Lin et al. The study of ultra-precision machining and residual stress for NiP alloy with different cuttingspeeds and
depth of cut. Journal of Materials Processing Technology,2000,97:200～210
38．方刚，曾攀．切削加工过程数值模拟的研究进展．力学进展，2001，31(3)：394～404
39．方刚，雷丽萍，曾攀．金属塑性成形过程延性断裂的准则及其数值模拟．机械工程学报，2002，38(增刊)：21～25
40．郑长卿，周利，张克实著．金属韧性破坏的细观力学及其应用研究．北京：国防工业出版社，1995．9
41. Ritchie R O, Thompson A W . On Macroscopic and Microscopic Analyses for Crack Initiation and Crack Growth Toughness in Ductile Alloys. Metall. Trans.,16A(1985):233～247
42. ANSYS Inc.ANSYS 6.0 APDL Programmer's Guide.ANSYS Inc,2001.3
43．陈精一，蔡忠国编著．电脑辅助工程分析：ANSYS使用指南．北京：中国铁道出版社，2001．4
44．《机械工程材料性能数据手册》编委会编．机械工程材料性能数据手册．北京：机械工业出版社，1994．12
45．赵吉文．二维金属切削过程计算机仿真及刀具几何参数优化．合肥工业大学，2002
46．嘉木工作室编著．UG18实体建模实例教程．北京：机械工业出版社，2002．5
47．清宏计算机工作室编著．Delphi编程技巧．北京：机械工业出版社，2001．1
48．韩伟峰编著．Delphi6程序设计教程．北京：清华大学出版社，2002．1
49. van Luttervelt C A , Childs T H C ed. Present situation and future trendsin modeling of machining operations. Keynote Paper. Annual of the CIRP,1998,47(2):587～626
50. Fang N, Jawahir IS. Analytical Prediction of the Chip Back-Flow Anglein Machining With Restricted Contact Grooved Tools.Journal of Manufacturing and Engineering,125(2003):210～219