Finite element modeling of hard turning process via a micro-textured tool
Finite element modeling of hard turning process via a micro-textured tool
复制标题
DOI：
10.1007/s00170-014-6747-x
复制
发表时间：
2015-06-01
影响因子：
3.4
通讯作者：
Park, Hyung Wook
中科院分区：
文献类型：
--
作者：
Kim, Dong Min;Bajpai, Vivek;Park, Hyung Wook
文献调查表明，在刀具前刀面上的微织构可以帮助减少在切屑-刀具界面处的摩擦，从而减少切削力。因此，目前的工作是基于有限元模拟的硬车削轴承钢（AISI 52100）。在刀具前刀面上考虑了四种类型的微观织构：无织构、垂直织构、平行织构和矩形织构。针对材料性质随温度变化的工件，考虑了Johnson-Cook（J-C）材料本构关系。在切割条件下进行了实验工作：类型，平行;边缘距离，0.195 mm;间距尺寸，0.110 mm;纹理高度，0.049 mm，以验证当前的加工模型。研究了刀具特征参数对切削力的影响规律。基于当前模型，观察到垂直形状显示出最小切削力。与非纹理化表面相比，预测有效摩擦系数最大降低28%。此外，纹理的大小（边缘距离，间距大小，纹理的高度）和工具-芯片界面上的摩擦系数的过程响应的影响进行了预测。在100 μ m的边缘距离，间距大小为100 μ m，和纹理的高度为50 μ m的垂直纹理表现出最有效的形状和尺寸的最小切削力和有效摩擦。它是模拟的切屑流角可以由刀具前刀面上的纹理的形状/大小。预计目前的模型可以进一步有助于其他硬质材料和复杂纹理形状/尺寸的表征。
Literature survey showed that the micro-textures on the tool rake face can help in reduction in friction at chip-tool interface and therefore, reduction in the cutting forces. Consequently, the current work is based on FE simulation of hard turning of bearing steel (AISI52100). Four types of micro-textures have been considered on the tool rake face: non-texture, perpendicular, parallel, and rectangle. Johnson-Cook (J-C) material constitutive law has been considered for the workpiece with temperature-dependent material properties. Experimental work has been performed at cutting conditions: type, parallel; edge distance, 0.195 mm; pitch size, 0.110 mm; and height of the texture, 0.049 mm to validate the current machining model. Parametric study of effect of tool feature parameters on the cutting forces has been performed. Based on the current model, it is observed that the perpendicular shape showed the minimum cutting force. The maximum reduction of 28 % was predicted in the effective coefficient of friction compared to the non-textured surface. Additionally, effect of size of the texture (edge distance, pitch size, texture height) and the friction factor at tool-chip interface on the process responses is predicted. The perpendicular texture at an edge distance of 100 mu m, pitch size of 100 mu m, and texture height of 50 mu m showed the most effective shape and size for the minimum cutting forces and effective friction. It is simulated that the chip flow angle can be governed by the shape/size of the texture on the tool rake face. It is expected that the current model can further be helpful in the characterization of other hard materials and complex texture shape/size.