微织构刀具织构参数优化仿真研究

During the cutting process of high-temperature nickel-based alloys, larger cutting forces can generate higher cutting temperatures, resulting in processing problems such as severe tool wear and poor machined surface quality. In the machining area on the rake face of the tool, designing micro-textures can improve the friction and lubrication state of the tool-chip contact surface during cutting, thereby improving the cutting performance of the tool. The finite element simulation software is used to conduct a simulation experiment on cutting nickel-based alloys with sinusoidal micro-textured tools. Through orthogonal experiments, the effects of five texture parameters of the sinusoidal micro-textured tool, namely texture edge distance, texture width, texture spacing, sinusoidal curve amplitude, and period length, on the cutting performance of the tool are studied, and the texture parameters of the sinusoidal micro-textured tool are optimized. The results show that the reduction degree of the main cutting force of the sinusoidal micro-textured tool is closely related to the texture parameters, and the influence degree of the texture parameters on the magnitude of the main cutting force is in the order of: texture edge distance > texture spacing > texture width > sinusoidal curve amplitude > period length. The cutting force, cutting temperature, and chip-breaking ability of the optimized tool are better than those of the non-textured tool before optimization.

高温镍基合金在切削加工过程中,较大的切削力会产生较高的切削温度,造成刀具磨损严重、加工表面质量差等加工难题。在刀具前刀面加工区域,设计微观织构(微织构)可以改善切削加工中刀-屑接触面的摩擦润滑状态,从而改善刀具的切削性能。采用有限元仿真软件对正弦型微织构刀具进行切削镍基合金的仿真实验,通过正交实验研究正弦型微织构刀具的织构刃边距、织构宽度、织构间距、正弦曲线幅值和周期长度5个织构参数对刀具切削性能的影响,并优化了正弦型微织构刀具的织构参数。结果表明:正弦型微织构刀具的主切削力降低程度与织构参数密切相关,且织构参数对主切削力大小的影响程度依次为:织构刃边距>织构间距>织构宽度>正弦曲线幅值>周期长度。优化后得到的刀具切削力、切削温度和断屑能力优于优化前无微织构刀具。