Modeling of Cutting Forces Under Hard Turning Conditions Considering Tool Wear Effect
Modeling of Cutting Forces Under Hard Turning Conditions Considering Tool Wear Effect
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DOI：
10.1115/1.1852571
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发表时间：
2005-05
影响因子：
4
通讯作者：
Yong Huang;S. Liang
中科院分区：
文献类型：
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作者：
Yong Huang;S. Liang
硬车削条件下切削力的定量理解对于热建模、刀具寿命估计、颤振预测和刀具状态监测非常重要。虽然在车削过程中的力建模方面已经有了大量的研究，但硬化材料的车削涉及几个独特的工艺条件，包括负刀具前角、大刀尖半径和快速刀具磨损。这些工艺条件需要在切削力分析中进行特殊处理。本文首先考虑刀具几何复杂性的影响，通过扩展二维机械力模型，建立了斜切屑形成力模型，从而解决了这些问题。利用遗传算法对机械力模型的系数进行了估计，克服了缺乏显式法向方程的缺点。然后，将二维刀具磨损力建模方法扩展到三维分析，以适应硬车削时低进给速度、小切削深度和较大刀尖半径的影响。总切削力是由于切屑形成的力和由于侧面磨损的力的线性总和。采用立方氮化硼（CBN）刀具在刀面渐进式磨损条件下，在实际切削条件下（低进给速度、小切削深度和慢切削速度）对淬硬52100轴承钢进行车削时，模型预测的切削力与实验结果吻合较好。
Quantitative understanding of cutting forces under hard turning conditions is important for thermal modeling, tool life estimation, chatter prediction, and tool condition monitoring purposes. Although significant research has been documented on the modeling of forces in the turning operation in general, turning of hardened materials involves several distinctive process conditions, including negative tool rake angle, large tool nose radius, and rapid tool wear. These process conditions warrant specific treatment in the analysis of cutting forces. This paper first addresses these issues by formulating an oblique chip formation force model through the extension of a two-dimensional (2D) mechanistic force model while considering the effect of tool geometry complexities. The coefficients of the mechanistic force model are estimated by applying a genetic algorithm in overcoming the lack of explicit normal equations. Then the forces occurring due to flank wear are modeled by extending a 2D worn tool force modeling approach into a three-dimensional analysis to accommodate the effect of low feed rate, small depth of cut, and relatively large tool nose radius in hard turning. The total cutting forces are the linear summation of forces due to chip formation and forces due to flank wear. The model-predicted forces match well with experimental results in the turning of hardened 52100 bearing steel under practical cutting conditions (low feed rate, small depth of cut, and gentle cutting speed) using cubic boron nitride (CBN) tools under the progressive tool flank wear conditions.