基于能量的微切削最小切削厚度有限元仿真研究

Finite element simulation of the minimum chipthicknessin micro-machining based on energy

针对微细切削加工技术中存在的影响加工质量和稳定性的最小切削厚度问题,建立了最小切削厚度模型,对在一定加工条件下的不同材料最小切削厚度的估值进行了研究。分析了微切削过程中工件与刀具圆弧半径接触面上分流点的位置和受力情况,从最小能量的角度建立了最小切削厚度的计算公式;建立了微细切削加工的正交切削有限元仿真模型,定义了用于仿真的工件材料的本构模型,运用ABAQUS仿真软件对工件与刀具圆弧半径接触处的单元能量进行了有限元仿真研究。研究结果表明:在微细切削加工过程中,工件与刀具圆弧半径接触处存在能量较小的一段分流区域,通过分流区域的位置可以对一定加工条件下的最小切削厚度进行估算;工件与刀具之间的摩擦系数是影响最小切削厚度的重要因素。

Aiming at the minimum chip thickness which affected the quality and stability in micro-machining,the model creation and the estimation of value in different machining condition for the minimum chip thickness were studied.The position and force condition of stagnant point on the contact surface between the workpiece and the radius of cutting tool in the process of micro-machining were analyzed.The calculation formula of the minimum chip thickness was created from the view of the minimum energy.The finite element simulation model of orthogonal machining was established and the constitutive model of material was identified.The finite element simulation of element energy on the contact surface between the workpiece and the radius of cutting tool was carried out by using the ABAQUS software.The results indicate that there is a stagnant area which has little energy on the contact surface of workpiece and the radius of cutting tool,the minimum chip thickness in certain machining condition can be estimated according to the position of the stagnant area.The friction coefficient of workpiece and tool is the important factor which affects the minimum chip thickness.