Modeling of Tool-Wear Based on Tool Temperatures and Decomposed Cutting Forces in Turning with Grooved Tools

沟槽刀具车削中基于刀具温度和分解切削力的刀具磨损建模

• 批准号: 0085126
• 负责人: Ibrahim Jawahir
• 金额: $ 15万
• 依托单位: University of Kentucky
• 依托单位国家: 美国
• 项目类别: Continuing Grant
• 财政年份: 2000
• 资助国家: 美国
• 起止时间: 2000-10-01 至 2003-09-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0085126&HistoricalAwards=false
• 关键词: Modeling; Tool; Wear; Based; Temperatures

This grant is aimed at modeling tool-wear in grooved tools based on its relationships with cutting forces, stresses, temperatures and tool-chip contact in 2-D machining and turning. Experimental work involves measurement of tool temperature distributions, tool-chip contact length and tool-wear parameters. The results from the experimental work will provide important modeling parameters and boundary conditions for a predictive 2-D model (numerical) for forces, stresses and temperatures. The first phase of the project is focused on establishing comprehensive relationships among tool-wear and tool temperatures, stresses and tool geometry parameters. The effects of a finite cutting edge radius on tool-wear and tool temperatures will also be investigated. In the second phase, turning experiments with grooved tools will be performed to collect data on 3-D tool-wear, temperatures, forces and tool-chip contact. A modeling approach based on decomposition of cutting forces at different wear regions of a grooved tool will be extended to correlate tool-wear with forces and temperatures using the effective 2-D chip-flow direction. The results from this approach will be used in developing an integrated hybrid 3-D predictive model, involving analytical-numerical-empirical approaches. The anticipated major benefit from this project is the development of a new, fundamental modeling approach for tool-wear. Machining operations constitute a large segment of the manufacturing sector in the US. There has been a growing need for developing robust models and methodologies to enable reliable and accurate predictions of machining performance measures in process planning to ensure the highest quality of machined products with maximized productivity. The tool-wear rate has significant correlation with other important machining performance measures such as chip-form/chip breakability, surface roughness/surface integrity and part accuracy. Traditional models for tool-life/tool-wear have been heavily empirical due to the complexity of the problem; hence, the current project advocates the use of a hybrid modeling methodology. The expected results from this project will provide fundamental new knowledge for tool-wear predictions in machining with grooved tools. The results will also serve process planners in selecting the most appropriate cutting tools and cutting conditions for maximized machining performance, especially with respect to tool-wear/tool-life.

该资助旨在基于切削力、应力、温度和二维加工和车削中刀具与切屑接触的关系，对沟槽刀具的刀具磨损进行建模。实验工作包括测量刀具温度分布、刀具-切屑接触长度和刀具磨损参数。实验工作的结果将为力、应力和温度的预测二维模型（数值）提供重要的建模参数和边界条件。该项目的第一阶段侧重于建立刀具磨损与刀具温度、应力和刀具几何参数之间的综合关系。有限切削刃半径对刀具磨损和刀具温度的影响也将被研究。在第二阶段，将进行带槽刀具的车削实验，以收集三维刀具磨损、温度、力和刀具与切屑接触的数据。基于槽形刀具不同磨损区域切削力分解的建模方法将扩展到使用有效的二维切屑流动方向将刀具磨损与力和温度关联起来。该方法的结果将用于开发一个集成的混合三维预测模型，包括分析-数值-经验方法。预计该项目的主要好处是开发了一种新的、基本的工具磨损建模方法。在美国，机械加工业务占制造业的很大一部分。越来越需要开发强大的模型和方法，以便在工艺规划中可靠和准确地预测加工性能指标，以确保加工产品的最高质量和最大的生产率。刀具磨损率与其他重要的加工性能指标（如切屑形状/切屑可破碎性、表面粗糙度/表面完整性和零件精度）有显著相关性。由于问题的复杂性，传统的刀具寿命/磨损模型在很大程度上是经验性的；因此，当前的项目提倡使用混合建模方法。该项目的预期结果将为槽形刀具加工中刀具磨损预测提供基本的新知识。这些结果还将为工艺规划者选择最合适的刀具和切削条件，以最大限度地提高加工性能，特别是在刀具磨损/刀具寿命方面。