微型车刀微孔织构设计及高速微车削试验

Design of Micro Hole Texture Tool and Experimental Study on High Speed Micro-turning

针对微型刀具高速微切削过程中磨损严重的问题,基于表面非光滑技术,在刀具表面进行微孔织构设计,并采用Deform-3D进行金属切削动态模拟分析。分析表明,前刀面带有微孔织构的微型车刀主切削力、刀尖最高温度、刀具磨损量,与无织构车刀相比都明显降低。利用微细电火花加工技术在微型车刀表面加工微孔织构,使用自行研制的高速微车削实验装置进行6061铝合金的微加工实验,并从刀具表面磨损状况、切屑形态、已加工表面粗糙度3个方面进行评价。实验结果表明,微孔织构在提高刀具减磨性能和已加工表面质量方面效果良好,微织构改善了切屑形态,增强了刀具排热、抗黏结性能。

Aimed at the serious problem of tool wear during micro-cutting process at high speed, the micro-hole texture was designed on tool face based on non-smooth technology of surface, and the dynamic simulation analysis of metal turning was carried out by using DEFORM-3D.The results show that the main cutting force, the maximum temperature of tool tip, and the wear loss on the rake face of the tools with micro-hole texture are decreased obviously as compared with the untexture tool.By utilizing micro-electric discharge machining （EDM） technology, the micro-hole texture was machined in the tool surface, and a micro-machining experiment of Aluminium alloy of 6061 with the micro hole texture tool was performed by a self-made high-speed micro-turning experimental device.The cutting properties were evaluated from three aspects,including chip form, tool wear condition and roughness of machined surface.The experimental results show that the micro-hole texture improves the wear resistance of tools and the quality of machined surface.Moreover,the micro texture improves the chip form, and enhances the heat rejection and anti-sticking performance of tools.