内冷车刀设计的结构和热复合分析方法及应用

Design method of topology optimization compound thermal analysis for internally cooled turning tool with application

为获得具有合理的内冷流道且力学性能好的内部循环冷却车刀结构,提出一种将结构拓扑优化设计与流固耦合有限元热设计两种设计分析方法相结合进行内冷车刀复合设计的方法。针对典型车刀的使用工况,采用带惩罚指数的固体各向同性微结构拓扑优化方法,在最大刚度条件下获得内部流道设计区域,并通过工程化重设计使得区域连通,保证刀具内部冷却液有效流动;建立流固耦合热场分析模型,以切削区域最高温度最小为目标,对刀具流道进行优化设计。设计结果表明,优化设计后的内冷刀具与传统内冷刀具相比,在相同的冷却流量、冷却液体积条件下,刀具结构的整体刚度提高、变形减少的同时,刀具最高温度有所降低,说明所提方法对内冷刀具的优化设计有效。该设计方法可以在所有循环内冷式刀具中通用。

To achieve good mechanical performance with a reasonable fluid channel layout for an internal cooled cutting tool,an optimal design method which combined structural topology and fluid-structure coupling thermal field analysis was suggested according to the structural characteristics of internal cooled cutting tool.The Solid Isotropic Microstructures with Penalization（SIMP）topology optimization method was applied to obtain internal flow channel areas under the greatest structure working condition.Through the engineering redesign,the areas were connected to ensure the coolant flow effectively in the internal channel.The fluid-structure coupling thermal field analysis design method was adopted to optimize tool flow channel by taking minimum the max temperature as objective.The design results showed that the stiffness of the optimal structure was increased,the deformation was decreased and the highest temperature was reduced at the same time by comparing with the traditional internal cooled cutting tool structure.The method was effective and could be used universally in the internal cooled tools designing.