基于有限元分析的PCD立铣刀铣削紫铜工艺参数研究

Research on the Processing Technology of PCD End-mill Milling Copper based on Finite Element Analysis

作为刀具材料的PCD以其高硬度、高耐磨性、高导热系数、低摩擦系数等优异的特性在有色金属加工中得到广泛应用。应用有限元分析软件ABAQUS,以焊接式PCD双刃立铣刀铣削过程的建模为基础,充分考虑刀具与工件的摩擦及弹塑性变形产生的热量、刀具与工件之间的热传导等因素,研究不同加工工艺参数(如:铣削速度vc、轴向铣削深度ap、每转进给量f)对刀具温度场分布和切削力的影响,得出刀具温度分布和切削力随铣削参数的变化趋势。仿真结果表明:刀具温度随铣削深度、每转进给量和转速增加而上升;但刀具温度对刀具寿命影响较小,在满足工件表面质量和加工效率的条件下,应尽量选择低转速、小铣削深度和小进给量。铣削深度对切削力的影响较大,当铣削转速在2400r/min^2800 r/min左右时,轴向铣削深度0.3mm,进给量0.2mm/r,可获得小的铣削力和较低的刀具温度,能延长PCD刀具寿命。

As tool material,PCD is widely used in nonferrous metal processing due to its excellent properties such as high hardness,high wear resistance,high thermal conductivity and low friction coefficient.With the application of the Finite element analysis software ABAQUS and the full consideration of the friction of tool and work-piece,the heat generated by the elastic-plastic deformation,and the heat transferring between the cutting tool and the work-piece,the effect of different processing parameters(such as milling speed vc,axial turn milling depth ap,and each feeding f)on the tool temperature field distribution and the cutting force was studied on the basis of the welded PCD double vertical milling cutter milling process modeling,and the change rules of the cutting tool temperature distribution and the cutting force along with the change of milling parameters concluded.The simulation results showed that the tool temperature increased with the increase of milling depth,feed per revolution and rotation speed.However,the tool temperature had little effect on the tool life.Given that the the required work-piece surface quality and machining efficiency were to meet,low speed,small milling depth and small feed should be selected as far as possible.Milling depth had a great influence on cutting force.When the milling speed was about 2400 r/min^2800 r/min,the axial milling depth 0.3 mm,and the feed 0.2 mm/r,the small milling force,the lower tool temperature,and the longer life of PCD tool were obtained.