Development of a simulation based method for a load dependent optimisation of cemented carbide tools for nickel-base alloys - Variable micro geometry along the cutting edge

开发基于模拟的方法，用于镍基合金硬质合金刀具的负载相关优化 - 沿切削刃的可变微观几何形状

• 批准号: 313918187
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2018-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/313918187?language=en
• 关键词: Development; simulation; based; method; load; Development; simulation; based; method; load

This knowledge transfer project proposal is based on the fundamental research project: Modelling of the thermo-mechanical loads and wear behavior for optimisation of cemented carbid twist drills. The former project focused on the three-dimensional FE-simulation of chip formation for the prediction of the influence of the cutting edge preparation on the tool load during drilling processes. The low spatial resolution and long calculation times lead to difficulties during the analysis of the simulation. Therefore, an alternative model was proposed. These simulations of orthogonal cutting are carried out, which represent different orthogonal cut on the first primary cutting edge of a drilling tool. This technique offered the advantage of higher spatial resolution and shorter calculation times and should be applied and extended for drilling and milling of nickel-base alloys. This includes the consideration of local process conditions like the radius-dependent cutting speed in drilling by using design of experiments. The tool wear is simulated by the model of Usui. The parametric description of the cutting edge can be used for the statistical modelling of the tool wear which provides a wear prediction for every possible combination of parameter values. Furthermore, the statistical model is used to find cutting edge parameters which minimize the tool wear. This approach is extended here to milling processes, which have characteristic variations of the uncut chip thickness during a single tool rotation. Furthermore, a method is developed for measuring prepared cutting edges. Finally, optimized tools are compared to standard tools in experimental tests.

此知识转移项目建议基于基本研究项目：热机械负载和磨损行为的建模，以优化胶结碳纤维扭曲钻。前项目的重点是芯片形成的三维FE模拟，以预测尖端制备对钻孔过程中刀具负荷的影响。低空间分辨率和较长的计算时间导致模拟分析过程中的困难。因此，提出了替代模型。进行这些正交切割的模拟，这代表了钻孔工具的第一个初级尖端上的不同正交切割。该技术提供了更高的空间分辨率和较短的计算时间的优势，应应用并扩展用于钻孔和铣削镍基合金。这包括考虑使用实验的设计，考虑了局部过程条件，例如钻孔中半径依赖的切割速度。工具磨损由USUI模型模拟。尖端的参数描述可用于工具磨损的统计建模，该模型为参数值的每种可能组合提供了磨损预测。此外，统计模型用于查找最小化工具磨损的尖端参数。此方法在这里扩展到铣削过程，在单个工具旋转过程中，它们具有未切割的芯片厚度的特征变化。此外，开发了一种用于测量准备的切割边缘的方法。最后，将优化的工具与实验测试中的标准工具进行了比较。