单颗磨粒对铣削毛刺碰撞作用的有限元仿真研究

Study on Simulation of Impact of Single Particle on Micro-milling Burr Via Finite Element Method

为了分析超声加工过程中磨粒对毛刺的碰撞作用,以2A12铝合金铣削加工中底边切出切削方向毛刺为对象,采用显示动力学有限元分析软件,对单磨粒接触碰撞作用进行仿真研究。分别研究不同碰撞位置、工具头振幅、磨粒形状和粒度因素对碰撞效果的影响。仿真结果表明:随着碰撞位置的增大,毛刺变形程度减小;随着工具头振幅的增加,毛刺剪切断裂效果更好;不同磨粒形状碰撞作用下,球形磨粒效果优于立方体磨粒;随着磨粒粒径的减小,碰撞效果更好。综合仿真结果得到的超声加工较优参数如下:工具头振幅 A=0.048 mm、球形磨粒、80# SiC磨粒。

To analyze the impact of the particles on the burrs in ultrasonic machining,the object that the cutting direction burr in the bottom edge of2A12 aluminum alloy milling,the finite element software based on the explicit dynamic method is applied to simulate the contact impact of single particles.The impact effect of the different position,tool amplitude,particle shape and size on the burrs are studied respectively.The simulated results show that,the degree of burr deformation decreases with the increasing of impact position;the burr shear fracture effect is better with the increasing of tool amplitude, the impact effect that the spherical particle is better than the cubic particle under different particle shape, the impact effect is better as the particle size of the abrasive decreases.The optimal parameters in ultrasonic machining obtained through the comprehensive simulated results are as follows:tool amplitude A =0.048 mm, spherical particle,80# SiC particle.