无偏置正交车铣切削层几何形状的解析模型和仿真

Mathematical Model and Simulation of Cutting Layer Geometry in Orthogonal Turn⁃Milling with Zero Eccentricity

正交车铣是一种高效精密的加工方法,它的切削层直接影响切屑变形、切削力和颤振从而进一步影响刀具寿命和加工质量等。为了探究正交车铣切削层的形成过程,研究了无偏置正交车铣切削层的几何形状。在不考虑动力学影响的情况下分析了无偏置正交车铣切削层的运动原理和形成过程,建立了其切入/切出角、切削深度和切削厚度的解析模型。通过试验验证了该解析模型的正确性,并分析了切削参数对铣刀切削层的影响。研究结果表明:无偏置正交车铣切削层的形成可划分为两个阶段;实际切屑形状与切削层几何形状仿真结果较为一致;切削参数对切削层几何形状影响的程度从大到小依次为:对应于工件每转的刀具进给量fa、转速比λ和切削深度ap。所建解析模型和研究结果为探究正偏心正交车铣切削层的形成过程提供了理论指导,为切削层几何形状的变化提供了定量分析,并为切削力和颤振的研究提供了理论指导。

Orthogonal turn-milling is a high-efficiency and precision machining method.Its cutting layer directly affects chip formation,cutting forces,and chatter,and further affects tool life,machining quality,etc.We studied The cutting layer geometry(CLG)in orthogonal turn-milling with zero eccentricity(OTMZE)is studied to explore orthogonal turn-milling cutting layer formation process.OTMZE principles of motion and formation processes are analyzed statically without considering kinetic influences.Mathematical models of the entrance and exit angles,cutting thickness,and cutting depth are established.In addition,these models are validated experimentally and some influences of cutting parameters on the tool cutting layer are analyzed.The results show that OTMZE cutting layer formation can be divided into two stages,chip shapes are nearly consistent with the simulated CLGs,and the most influencial parameter in affecting the cutting layer is found to be the tool feed per revolation of workpiece fa,followed by the ratio of the tool and workpiece speedsλand the cutting depth ap.These models and results can provide theoretical guidance to clarify formation processes and quantitatively analyze changes in cutting layer geometry during OTMZE.In addition,they offer theoretical guidelines for cutting forces and chatter.