车削中三维复杂断屑槽刀具断屑仿真研究

FEM simulation of chip breakage in turning with 3D complicate-grooved insert

为有效缩短现有断屑槽刀具的设计周期、降低设计成本,采用有限元方法模拟了切削过程中切屑折断过程。利用Solid Works软件建立了三种刀具的三维模型,并在Deform 3D软件中对车削45钢工件过程进行了三维切削仿真。其中,工件材料采用了Johnson-Cook模型和Cockroft-Latham韧性断裂准则,仿真模型采用了有效参数设置以保证数值计算精度与效率。通过仿真研究了不同切削参数下的切屑形态、断屑过程及主切削力等。研究结果表明,仿真结果与试验结果吻合良好,该仿真模型及方法能有效应用于断屑槽刀具断屑性能研究,是三维复杂断屑槽刀具设计和切削参数优化的一种新方法。

In order to shorten designing cycle and reduce designing cost of the grooved inserts, FEM method was used to simulate the chip breaking process during mental cutting process. SolidWorks software was used to build three-dimensional model of three kinds inserts for turning, then Deform 3D software was used to set up the 3D cutting FEM model of turning 45 steel workpiece process. The Johnson-Cook model and Cockroft-Latham ductile model were used for workpiece material and the effective parameters were set for ensuring the calculating precision and efficiency. The chip morphology, chip breakage process and cutting force under different cutting parameters were researched with FEM process. The results indicate that the simulated results are consistent to experimental results and the simulation model and method in the paper can be used for researching chip breaking ability of grooved inserts effectively, which is a new method for designing 3D compli- cate-grooved inserts and optimizing cutting parameters.