Prediction of Cutting Forces, Tool Stresses, Temperatures and Tool Life in High Speed Machining

高速加工中切削力、刀具应力、温度和刀具寿命的预测

• 批准号: 9821020
• 负责人: Taylan Altan
• 金额: $ 21.7万
• 依托单位: Ohio State University Research Foundation -DO NOT USE
• 依托单位国家: 美国
• 项目类别: Continuing Grant
• 财政年份: 1999
• 资助国家: 美国
• 起止时间: 1999-04-15 至 2003-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=9821020&HistoricalAwards=false
• 关键词: Prediction; Cutting; Forces; Tool; Stresses

In high-speed and high-precision machining, the interactions between the cutting tool and the workpiece are extremely important and complex. They affect tool life, process economics, and surface integrity of the machined product. To understand these interactions, finite element method (FEM) based metal flow simulation techniques will be used to establish the effect of process conditions (feed rate, depth of cut, cutting speed) upon cutting forces, tool temperatures and stresses, and tool failure. The project consists of the following tasks: (1) Orthogonal turning and milling tests will be conducted to establish a methodology for determining the flow stress data under high strain rate, strain and temperature conditions encountered in machining; (2) A computer program will be developed to predict forces, stresses, and temperatures in three-dimensional practical machining processes such as face milling, drilling, and ball-end milling; and (3) A wear model will be validated to predict tool wear in function of process variables and tool material and coating. Modeling techniques based on the physics of the cutting process will be used to demonstrate how to estimate tool wear, improve tool and insert design, and optimize process conditions. The results of this project are expected to contribute significantly to the fundamental understanding of metal cutting operations; and, reducing the amount of experimentation needed to establish and optimize high speed machining operations in an industrial environment.

在高速高精度加工中，刀具与工件之间的相互作用是极其重要和复杂的。 它们影响刀具寿命、加工经济性和加工产品的表面完整性。 为了理解这些相互作用，将使用基于有限元法（FEM）的金属流动模拟技术来确定工艺条件（进给速度、切削深度、切削速度）对切削力、刀具温度和应力以及刀具失效的影响。 本计画包括以下工作：（1）进行正交车削与铣削实验，以建立一套在高应变率、应变与温度条件下，确定切削加工流变应力数据的方法;（2）开发计算机程序，预测面铣、钻孔、和球头铣削;和（3）磨损模型将被验证，以预测刀具磨损的过程变量和刀具材料和涂层的函数。 基于切削过程物理的建模技术将用于演示如何估计刀具磨损，改进刀具和刀片设计，以及优化工艺条件。 该项目的结果预计将大大有助于对金属切削操作的基本理解;并减少在工业环境中建立和优化高速加工操作所需的实验量。