基于ABAQUS的TC4钛合金微铣削有限元仿真

Micro Milling Finite Element Simulation of TC4 Titanium Alloy Based on ABAQUS

当实际切削用量减小到微米级别时,传统铣削仿真无法对微铣削表现出的尺度效应和最小切削厚度等现象进行准确描述。以TC4钛合金为研究对象,建立考虑应变梯度理论修正的Johnson-Cook本构模型,采用ALE自适应技术控制网格畸变过大的问题,运用ABAQUS有限元软件对微铣削加工过程进行有限元模拟,获得反映尺度效应的微铣削模型,进而分析刃倾角和切削刃钝圆半径对切削过程的影响,以及主轴转速和每齿进给量对铣削力的影响,揭示了微切削区域塑性变形规律。

With the actual cutting parameters reduced to the micron level,micro milling shows scale effect and other phenomena,which can not be accurately described by traditional milling simulation.In this paper,TC4 titanium alloy is taken as the research object,Johnson-Cook constitutive model is established considering the modification of strain gradient theory.And the excessive mesh distortion occurred in the process of simulation has been solved by ALE adaptive technology.The finite element software ABAQUS is used to simulate the micro milling process,and the micro milling model reflecting the scale effect is obtained.Furthermore,the influence of edge inclination,blunt radius of the cutting edge on the cutting process,the influence of spindle speed and feed rate of each tooth on the milling force are revealed,and the shaping deformation rule in the micro cutting area are also revealed.