基于弹塑性平面应变力学原理的新型直角铣削实验设计

Design of New Type Orthogonal Milling Experiment based on Elastic-plastic Plane Strain Mechanics Principle

根据弹塑性平面应变力学原理设计了直角铣削实验,研制出专用实验装置,研究了切削力在加工坐标系和测量坐标系之间的数学变换、单位切削力计算以及切削刃尺寸效应等实验内容和细节,总结出了正交铣削实验设计和测试原则。以航空铝合金材料为对象进行直角铣削力测试,通过与切削理论公示计算结果比较验证了直角铣削实验设计的可靠性。将该直角铣削实验在计算切屑与前刀面摩擦系数和验证正交切削有限元模型方面进行了应用。本文设计的直角铣削实验将为深入研究变厚度铣削加工机理和铣削加工建模仿真提供实验技术支持。

A new type of orthogonal milling experiment under plane sta＇ain state was designed according to elastic-plastic mechanics principle. The special experiment device was developed, and the orthogonal milling experiment theory and method were founded, which included mathematics conversion between actual and measured coordinate systems, calculating of unit cutting forces, size effect of the cutting edge and experiment design and testing principles. The orthogonal milling force testing experiments of aviation aluminum-alloy 7050-T7451 were performed. The experimental data were compared with calculated cutting forces from theoretical formula and found to be in good agreement. Finally, the orthogonal milling experiment was applied to calculate average friction coefficient on the chip-tool interface and validate finite element model of milling simulation. The work of this paper provides a new experiment scheme for cutting experiment which can be used to study milling process mechanism and support milling modeling and simulation.