基于DEFORM-3D的7055铝合金三维钻削有限元分析

Finite element analysis of 3D drilling of 7055 aluminum alloy based on DEFORM-3D

旨在填补7055铝合金三维钻削有限元模拟方面的不足,以T6态7055铝合金为研究对象,选用两种不同刀具对其切削力、切屑形态及切削过程应力分布进行实验和仿真分析。实验和仿真结果表明:钻削力与钻削速度呈负相关,与进给量呈明显的正相关;钻削速度越大、进给量越小,钻削力的实验值和仿真值的误差越小;麻花钻钻削时,切屑卷曲直径和切屑变形厚度的实验值和仿真值一致性高达94%,三刃钻钻削时,误差较麻花钻大,但误差低于15%,属于误差允许范围;横刃钻削应力与钻削中心距离呈负相关,麻花钻钻削时,有明显的最小切削刃钻削应力,大概在距离钻削中心2 mm处;在稳态钻削阶段,三刃钻的切削刃钻削应力明显高于麻花钻,进给量为0.2 mm/r时,在钻削过程的后期,麻花钻的切削刃钻削应力的增大趋势较三刃钻明显。

In order to fill the insufficience in finite element simulation of 3D drilling of 7055 aluminum alloy, the T6 treated 7055 aluminum alloy was selected as the research object, the simulation analysis and experiment of cutting force, chip shape and stress distribution were carried out with two different tools. The experimental results show that the drilling force is negatively correlated with the drilling speed and shows a positive correlation with the feed rate. The higher the drilling speed, and the smaller the feed rate, the smaller the error between the experimental value and the simulation value of the drilling force. The consistency between experimental and simulation values of the crush diameter and the chip deformation thickness is as high as 94%, and the error is less than 15% when drilling with the twist drill, which belongs to the error tolerance range. The horizontal cutting stress has a negative correlation with the drilling center distance, and the twist drill has obvious minimum cutting. The drilling stress of the cutting edge of the grooved drilling is obviously higher than that of the twist drill, and the feed rate is 0.2 ram/ r. In the later period of drilling process, the drilling stress of the cutting edge of the twist drill is increasing obviously.