医用钛合金切削过程有限元仿真与试验研究
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摘要
钛合金TC4是一种综合性能优异的新型材料,在医疗、航空等领域的应用越来越广泛,但同时钛合金TC4也是一种难切削的金属材料,研究其切削过程对实际生产有着重要的现实意义。本文围绕医用钛合金(TC4)切削过程的有限元仿真和切削参数优化,主要作了以下几个方面的研究工作：
1.分析了金属切削过程切削层变形理论及材料非线性、几何非线性变形理论,研究了弹塑性大变形有限元求解过程,为进行TC4切削过程有限元仿真分析奠定了基础。
2.建立了基于Deform-3D有限元软件平台的TC4切削过程有限元仿真模型,对金属切削过程有限元仿真关键技术进行了研究。
3.通过仿真,研究了TC4切削过程中不同切削参数对切削力、切削温度的影响规律。
4.进行了TC4切削试验,分析了切削速度、每齿进给量与表面粗糙度之间的关系。
5.优化了TC4切削加工工艺参数,并通过了实际生产验证。
本文的研究对提高医用钛合金零件加工效率和加工质量,实现其高效精密铣削加工,促进医用钛合金材料的推广应用具有重要的意义。
Titanium alloy TC4 is a kind of new and reliable performance material which has been widely applied in medical, aviation fields and so on. But it is also a kind of material difficult to cut, so studying the cutting theory and cutting process of TC4 has an important and practical meaning. The main works of this paper focus on the finite element simulation of cutting process and cutting parameters optimization of the medical titanium alloy (TC4). The detailed contents are as follows:
1. Analyzed the metal-cutting deformation theories including cutting-layer deformation theory, material nonlinearity deformation theory and geometric non-linear deformation theory. Studied the elastic-plastic large deformation finite element solution process. All the works made a preparation for the finite element simulation of TC4 cutting process.
2. Built a finite element simulation model of TC4 cutting process based on Deform-3D finite element software platform and the key technologies about the finite element simulation of metal cutting process were studied.
3. By simulations, studied the influences of different cutting parameters on the cutting force and cutting temperature in the cutting process.
4. Analyzed the relationships between the surface roughness and the cutting speed, feed rate per tooth through TC4 cutting tests.
5. Optimized cutting parameters of TC4 and it was verified by actual production.
The researches of this paper have an important significance for promoting the extensive application and high efficiency machining of the medical titanium alloy.
1.分析了金属切削过程切削层变形理论及材料非线性、几何非线性变形理论,研究了弹塑性大变形有限元求解过程,为进行TC4切削过程有限元仿真分析奠定了基础。
2.建立了基于Deform-3D有限元软件平台的TC4切削过程有限元仿真模型,对金属切削过程有限元仿真关键技术进行了研究。
3.通过仿真,研究了TC4切削过程中不同切削参数对切削力、切削温度的影响规律。
4.进行了TC4切削试验,分析了切削速度、每齿进给量与表面粗糙度之间的关系。
5.优化了TC4切削加工工艺参数,并通过了实际生产验证。
本文的研究对提高医用钛合金零件加工效率和加工质量,实现其高效精密铣削加工,促进医用钛合金材料的推广应用具有重要的意义。
Titanium alloy TC4 is a kind of new and reliable performance material which has been widely applied in medical, aviation fields and so on. But it is also a kind of material difficult to cut, so studying the cutting theory and cutting process of TC4 has an important and practical meaning. The main works of this paper focus on the finite element simulation of cutting process and cutting parameters optimization of the medical titanium alloy (TC4). The detailed contents are as follows:
1. Analyzed the metal-cutting deformation theories including cutting-layer deformation theory, material nonlinearity deformation theory and geometric non-linear deformation theory. Studied the elastic-plastic large deformation finite element solution process. All the works made a preparation for the finite element simulation of TC4 cutting process.
2. Built a finite element simulation model of TC4 cutting process based on Deform-3D finite element software platform and the key technologies about the finite element simulation of metal cutting process were studied.
3. By simulations, studied the influences of different cutting parameters on the cutting force and cutting temperature in the cutting process.
4. Analyzed the relationships between the surface roughness and the cutting speed, feed rate per tooth through TC4 cutting tests.
5. Optimized cutting parameters of TC4 and it was verified by actual production.
The researches of this paper have an important significance for promoting the extensive application and high efficiency machining of the medical titanium alloy.
引文
[1]卞化梅,牛小铁,陈金英,郭勇.基于MATLAB的切削力测量实验数据处理及分析.煤矿机械.2008(2)：36-37
[2]李亮,何宁,何磊,王珉.高速铣削铝合金时切削力和表面质量影响因素的试验研究.工具技术.2002(42)：16-19
[3]周林,殷侠.数据采集与分析技术.第1版.西安：西安电子科技大学出版社,2005
[4]王娜,艾长胜,李国平,孙选.数控机床切削力间接测量研究.组合机床与自动化加工技术.2007(8)：22-24,27
[5]冀玉梅,赵东升.基于伺服电流与切削力关系的间接测量技术研究.机械与电子.2007(10)：40-42
[6]阎海鹏.高速铣削铝合金切削温度的研究.南京理工大学研究生论文.2004
[7]舒畅.高速铣削钛合金的切削温度研究.南京航空航天大学研究生论文.2005
[8]阎光明,杨巧风.0Cr15Ni7M02Al不锈钢铣削加工刀具磨损研究.工具技术.2008(11)：26-28
[9]杜随更,吕超,任学军,杨振朝.钛合金TC4高速铣削表面形貌及表层组织研究.航空学报.2008(6)：1710-1715
[10]史兴宽,杨巧凤,蔡伟,张明贤.钛合金TC4高速铣削表面完整性的研究.航空制造技术.2001(1)：30-35
[11]M E Merchant, Basic mechanics of the metal cutting process, J. Appl. Mech.11,1944, A168-A175
[12]V. Piispanen, Theory of formation of metal chips, J. Appl. Phys.1948(19):867-881
[13]E. H. Lee, B. W. Shaffer, The theory of Plasticity applied to a problem of machining, J. Appl. mech.1951(18):405-413
[14]E. D. Doyle, J. G.Home, D. Tabor. Fricitional Interactions between Chip and Rake Face in Continuous Chip Formation[J]. Por.R.Sco.Lonndon A 366,1979:173-183.
[15]W. B. Palmer, P. L. B. Oxler. Mechanics of Orthogonal Machining[J]. Proc. Inst. Mech. Engrs,1959(173):623-638
[16]K. J. Trigger, B. T. Chao. An alytical Evaluation of Metal Cutting Temperature [J]. Trans. ASME,1951(73):56-68
[17]Lajczok. M. R. A Study of Aspects of Metal Cutting by the Finite Element Method. [Ph.D dissertation]. NC StateUniversity.1980,1-20
[18]Usui. E, Maekawa. K, Shirakash. T. Simulation analysis of the buil-up edge formation in machining of low carbon steel. Bull Jan Soc Process Eng.1981 (4):237-242.
[19]Iwata. K, Osakdoa. K, Terasaka. T. Process Modeling of Orthogonal metal Cutting by the Rigid-plastic Finite Element Method. Tran ASME J Eng Mater Technology. 1984(106):132-138
[20]Komvopoulos. F. K, Erpenbeck S A. Modeling of Orthogonal Metal Cutting [J]. Trans ASME J Eng Ind.1991(113):253-267
[22]梁磊.金属切削仿真及实验研究.西安理工大学,硕士学位论文.2006
[23]Klamecki. B. E. Incipient chip formation in metal cutting-a three dimension finite element analysis. [Ph.D dissertatlon], Urbana:University of Illinois at Urbana Chanpalgn. 1973:1-10
[24]Lin Zone-Ching,Lai Wun-Lin,Lin H Y,Liu C R.The study of ultra-precision machining and residual stress for NiP alloy with different cutting speeds and depth of cut.Journal of Materials Processiflg Technology.2000(97):200-210
[25]Sasahara. H, Obikawa. T..FEM Analysis of Cutting Sequence Efcet on Mechanical Characteristics in Machined Layer [J]. Journal of Materials Processing Technology. 1996(62):448-453
[26]吴红兵,刘刚,柯映林,董辉跃.钛合金的已加工表面残余应力的数值模拟[J].浙江大学学报(工学版).2007(8)：1389-1393
[27]史兴宽,杨巧凤,张明贤,陈明,张树全,宋良煌,唐晓兰.钛合金TC4高速铣削表面的温度场研究.航空制造技术.2002(1)：34-37
[28]苌浩,何宁,满忠雷.TC4的铣削加工中铣削力和刀具磨损研究.航空精密制造技术.2003(3)：30-33
[29]李德华,陈志勇.钛合金切削加工刀具材料选用与加工工艺方法.湖北航天科技.2005(5)：32-37,17
[30]何秀梅,洪宝英.钛合金的切削加工工艺分析.航空精密制造技术.2005(6)：59-60
[31]沈中,孙暄,刘钢,陈明.基于平均切削厚度钛合金TC4铣削机理.上海交通大学学报.2007(4)：614-623
[32]许鸿昊,左敦稳,朱笑笑,张振金,赵灿,王珉.拉伸装夹对TC4钛合金铣削表面质量的影响.应用科学学报.2008(1)：106-110
[33]陈日曜.金属切削原理.第2版.北京：机械工业出版社,2005
[34]陈明祥.弹塑性力学.第1版.北京：科学出版社,2007
[35]王勖成,邵敏.有限元法基本原理与数值方法.第2版.北京：清华大学出版社出版社,1997
[36]吴国荣.大变形条件下材料本构关系研究.浙江海洋学院学报(自然科学版). 2007(3)：285-288,299
[37]梁磊.金属正交切削仿真及实验.西安理工大学硕士学位论文,2006
[38]周朝辉,曹海桥,吉卫,何大均,王孝培.DEFORM有限元系统软件及其应用[J].计算机应用.2003(4)：51-52
[39]DEFORMTM 3D Version (sp1) User's Manual. Oct.18.2007
[40]刘东,陈五一.钛合金TC4切削过程流动应力模型研究.塑性工程学报.2008(1)：167-171
[41]曾正明.实用有色金属材料手册.第2版.北京：机械工业出版社,2008
[42]陈线火.Marc有限元实例分析教程.第1版.北京：机械工业出版社,2002
[43]王霄,卢树斌,高传玉.高速金属切削的摩擦分析及有限元模拟.润滑与密封.2007(1)：129-131
[44]Furukawa Y, Moronuki N., Effect of material properties on ultra-precise cutting process, Ann CIRP.1988(37):113-120
[45]A.G.Mamalis, M.Horvath, A.S.Branis, D.E.Manolakos, Finite element simulation of chip formation in orthogonal metal cutting,Journal of Materials Processing Technology.2001 (110)19-27
[461董兆伟,张以都,刘胜永,万晓航.分层切削加工有限元仿真分析.航空制造技术.2007(7)：75-78
[47]倪为国,潘延华.铣削刀具技术及应用实例.第1版.北京：化学工业出版社,2007
[48]郑文虎.难切削材料加工技术.第1版.北京：国防工业出版社,2008
[49]王先逵.机械制造工艺学.第1版.北京：机械工业出版社,2006
[50]南通纵横国际股份有限公司机床制造分公司.数控加工中心XH713A说明书,2006
[2]李亮,何宁,何磊,王珉.高速铣削铝合金时切削力和表面质量影响因素的试验研究.工具技术.2002(42)：16-19
[3]周林,殷侠.数据采集与分析技术.第1版.西安：西安电子科技大学出版社,2005
[4]王娜,艾长胜,李国平,孙选.数控机床切削力间接测量研究.组合机床与自动化加工技术.2007(8)：22-24,27
[5]冀玉梅,赵东升.基于伺服电流与切削力关系的间接测量技术研究.机械与电子.2007(10)：40-42
[6]阎海鹏.高速铣削铝合金切削温度的研究.南京理工大学研究生论文.2004
[7]舒畅.高速铣削钛合金的切削温度研究.南京航空航天大学研究生论文.2005
[8]阎光明,杨巧风.0Cr15Ni7M02Al不锈钢铣削加工刀具磨损研究.工具技术.2008(11)：26-28
[9]杜随更,吕超,任学军,杨振朝.钛合金TC4高速铣削表面形貌及表层组织研究.航空学报.2008(6)：1710-1715
[10]史兴宽,杨巧凤,蔡伟,张明贤.钛合金TC4高速铣削表面完整性的研究.航空制造技术.2001(1)：30-35
[11]M E Merchant, Basic mechanics of the metal cutting process, J. Appl. Mech.11,1944, A168-A175
[12]V. Piispanen, Theory of formation of metal chips, J. Appl. Phys.1948(19):867-881
[13]E. H. Lee, B. W. Shaffer, The theory of Plasticity applied to a problem of machining, J. Appl. mech.1951(18):405-413
[14]E. D. Doyle, J. G.Home, D. Tabor. Fricitional Interactions between Chip and Rake Face in Continuous Chip Formation[J]. Por.R.Sco.Lonndon A 366,1979:173-183.
[15]W. B. Palmer, P. L. B. Oxler. Mechanics of Orthogonal Machining[J]. Proc. Inst. Mech. Engrs,1959(173):623-638
[16]K. J. Trigger, B. T. Chao. An alytical Evaluation of Metal Cutting Temperature [J]. Trans. ASME,1951(73):56-68
[17]Lajczok. M. R. A Study of Aspects of Metal Cutting by the Finite Element Method. [Ph.D dissertation]. NC StateUniversity.1980,1-20
[18]Usui. E, Maekawa. K, Shirakash. T. Simulation analysis of the buil-up edge formation in machining of low carbon steel. Bull Jan Soc Process Eng.1981 (4):237-242.
[19]Iwata. K, Osakdoa. K, Terasaka. T. Process Modeling of Orthogonal metal Cutting by the Rigid-plastic Finite Element Method. Tran ASME J Eng Mater Technology. 1984(106):132-138
[20]Komvopoulos. F. K, Erpenbeck S A. Modeling of Orthogonal Metal Cutting [J]. Trans ASME J Eng Ind.1991(113):253-267
[22]梁磊.金属切削仿真及实验研究.西安理工大学,硕士学位论文.2006
[23]Klamecki. B. E. Incipient chip formation in metal cutting-a three dimension finite element analysis. [Ph.D dissertatlon], Urbana:University of Illinois at Urbana Chanpalgn. 1973:1-10
[24]Lin Zone-Ching,Lai Wun-Lin,Lin H Y,Liu C R.The study of ultra-precision machining and residual stress for NiP alloy with different cutting speeds and depth of cut.Journal of Materials Processiflg Technology.2000(97):200-210
[25]Sasahara. H, Obikawa. T..FEM Analysis of Cutting Sequence Efcet on Mechanical Characteristics in Machined Layer [J]. Journal of Materials Processing Technology. 1996(62):448-453
[26]吴红兵,刘刚,柯映林,董辉跃.钛合金的已加工表面残余应力的数值模拟[J].浙江大学学报(工学版).2007(8)：1389-1393
[27]史兴宽,杨巧凤,张明贤,陈明,张树全,宋良煌,唐晓兰.钛合金TC4高速铣削表面的温度场研究.航空制造技术.2002(1)：34-37
[28]苌浩,何宁,满忠雷.TC4的铣削加工中铣削力和刀具磨损研究.航空精密制造技术.2003(3)：30-33
[29]李德华,陈志勇.钛合金切削加工刀具材料选用与加工工艺方法.湖北航天科技.2005(5)：32-37,17
[30]何秀梅,洪宝英.钛合金的切削加工工艺分析.航空精密制造技术.2005(6)：59-60
[31]沈中,孙暄,刘钢,陈明.基于平均切削厚度钛合金TC4铣削机理.上海交通大学学报.2007(4)：614-623
[32]许鸿昊,左敦稳,朱笑笑,张振金,赵灿,王珉.拉伸装夹对TC4钛合金铣削表面质量的影响.应用科学学报.2008(1)：106-110
[33]陈日曜.金属切削原理.第2版.北京：机械工业出版社,2005
[34]陈明祥.弹塑性力学.第1版.北京：科学出版社,2007
[35]王勖成,邵敏.有限元法基本原理与数值方法.第2版.北京：清华大学出版社出版社,1997
[36]吴国荣.大变形条件下材料本构关系研究.浙江海洋学院学报(自然科学版). 2007(3)：285-288,299
[37]梁磊.金属正交切削仿真及实验.西安理工大学硕士学位论文,2006
[38]周朝辉,曹海桥,吉卫,何大均,王孝培.DEFORM有限元系统软件及其应用[J].计算机应用.2003(4)：51-52
[39]DEFORMTM 3D Version (sp1) User's Manual. Oct.18.2007
[40]刘东,陈五一.钛合金TC4切削过程流动应力模型研究.塑性工程学报.2008(1)：167-171
[41]曾正明.实用有色金属材料手册.第2版.北京：机械工业出版社,2008
[42]陈线火.Marc有限元实例分析教程.第1版.北京：机械工业出版社,2002
[43]王霄,卢树斌,高传玉.高速金属切削的摩擦分析及有限元模拟.润滑与密封.2007(1)：129-131
[44]Furukawa Y, Moronuki N., Effect of material properties on ultra-precise cutting process, Ann CIRP.1988(37):113-120
[45]A.G.Mamalis, M.Horvath, A.S.Branis, D.E.Manolakos, Finite element simulation of chip formation in orthogonal metal cutting,Journal of Materials Processing Technology.2001 (110)19-27
[461董兆伟,张以都,刘胜永,万晓航.分层切削加工有限元仿真分析.航空制造技术.2007(7)：75-78
[47]倪为国,潘延华.铣削刀具技术及应用实例.第1版.北京：化学工业出版社,2007
[48]郑文虎.难切削材料加工技术.第1版.北京：国防工业出版社,2008
[49]王先逵.机械制造工艺学.第1版.北京：机械工业出版社,2006
[50]南通纵横国际股份有限公司机床制造分公司.数控加工中心XH713A说明书,2006