Prediction of Cutting Forces for Chamfered Inserts Based on Modified Slip-line Field Model#br#

doi:10.3969/j.issn.1004-132X.2021.08.002

China Mechanical Engineering ›› 2021, Vol. 32 ›› Issue (08): 890-906.DOI: 10.3969/j.issn.1004-132X.2021.08.002

Previous Articles Next Articles

Prediction of Cutting Forces for Chamfered Inserts Based on Modified Slip-line Field Model#br#

ZHUANG Kejia1，2;HU Cheng1,2;DAI Xing3;PU Donglin4;DING Han3

1.School of Mechanical and Electronic Engineering,Wuhan University of Technology,Wuhan，430070
2.Hubei Digital Manufacturing Key Laboratory,Wuhan University of Technology,Wuhan，430070
3.State Key Laboratory of Digital Manufacturing Equipment and Technology,Huazhong University of Science and Technology,Wuhan，430074
4.Wuxi Research Institute of Huazhong University of Science and Technology,Wuxi,Jiangsu，214000

Online:2021-04-25 Published:2021-05-10

基于修正滑移线场模型的倒棱刀具切削力预测

庄可佳1,2;胡诚1,2 ;代星3;浦栋麟4;丁汉3

1.武汉理工大学机电工程学院, 武汉, 430070
2.武汉理工大学数字制造湖北省重点实验室, 武汉, 430070
3.华中科技大学数字制造装备与技术国家重点实验室, 武汉, 430074
4.华中科技大学无锡研究院, 无锡, 214000

通讯作者: 胡诚（通信作者），男，1996年生，硕士研究生。研究方向为加工过程力热解析预测、切削机理建模和有限元仿真。E-mail:hucheng828@whut.edu.cn。
作者简介:庄可佳，男，1988年生，副教授。研究方向为数控加工过程物理仿真、表面完整性、制造可靠性等。E-mail:zhuangkj@whut.edu.cn。
基金资助:
国家自然科学基金(51705385,51975237)；
装备预研领域基金（61400020108）

Abstract

Abstract: Based on the material plasticity slip-line theory and flow state analysis ahead of tool edge, a modified slip-line field model was proposed considering material stagnation zone (dead metal zone), and pre-cut region in negative-rake-angle cutting processes with chamfered insert. Furthermore, an iterative sollution to material shear flow stress and edge front cutting geometry was suggested. The relationships of chamfered edge geometry and slip-line field geometry were disclosed. An analytical approach to the orthogonal cutting force prediction method was developed by applying the presented model to the cutting processes with chamfered insert. Verifications including finite element simulations and orthogonal cutting trials were carried out for the modified slip-line field model and prediction method of cutting forces. Average errors are all less than 10% in comparisons of predictions and simulations as well as measurements. Results provide references for investigating the influences of edge geometries on material flow characteristics and tool cutting performances.

Key words: slip-line field, chamfered edge, dead metal zone, cutting force prediction

摘要： 基于材料塑性滑移理论与刀具刃前材料流动状态分析，提出了一种考虑倒棱刀具负前角切削过程下的材料滞流区（死区）和预剪区的修正滑移线场模型，并给出了材料流动剪切应力和刃前切削几何参数的迭代求解方法，揭示了倒棱刃口几何形状与滑移线场几何参数之间的变化规律。将此模型应用于倒棱刀具切削过程，得到了适用于倒棱刀具正交切削力的预测方法。采用有限元仿真和切削试验相结合的方法对所提出的滑移线场模型和切削力预测方法分别进行了验证，模型预测结果与仿真结果和试验测量结果对比误差均在10%以内。研究结果为研究倒棱几何形状对工件材料流动特性和刀具切削性能的影响提供了参考。

关键词: 滑移线场, 倒棱刃口, 死区, 切削力预测

CLC Number:

ZHUANG Kejia, HU Cheng, DAI Xing, PU Donglin, DING Han. Prediction of Cutting Forces for Chamfered Inserts Based on Modified Slip-line Field Model#br#[J]. China Mechanical Engineering, 2021, 32(08): 890-906.

庄可佳, 胡诚, , 代星, 浦栋麟, 丁汉. 基于修正滑移线场模型的倒棱刀具切削力预测[J]. 中国机械工程, 2021, 32(08): 890-906.

References

［1］邬本祥，陈政伟，黄隆荣，等. 刀具刃口制备技术研究进展［J］. 工具技术, 2019, 53(1):8-14.

WU Benxiang, CHEN Zhengwei, HUANG Longrong, et al. State of Art in Cutting Tool Edge Preparation Technologies［J］. Tool Engineering, 2019, 53(1):8-14.

［2］CHOUDHURY I A, SEE N L, ZUKHAIRI M. Machining with Chamfered Tools［J］. Journal of Materials Processing Technology, 2005, 170(1/2):115-120.

［3］JACOBSON S, WALLN P. A New Classification System for Dead Zones in Metal Cutting［J］. International Journal of Machine Tools and Manufacturing, 1988, 28(4):529-538.

［4］万蕾. 基于有限元方法的金属切削过程研究［D］. 上海：上海工程技术大学, 2016:29-53.

WAN Lei. Numerical Analysis of Metal Cutting Process［D］. Shanghai:Shanghai University of Engineering Science, 2016:29-53.

［5］USUI E, KIKUCHI K, HOSHI K. The Theory of Plasticity Applied to Machining with Cut-away Tools［J］. Journal for Engineering for Industry, 1964, 86(2):95-104.

［6］LEE E, SHAFFER B W. The Theory of Plasticity Applied to a Problem of Machining［J］. Journal of Applied Mechanics, 1951, 18:405.

［7］史艳红, 赵先锋, 姜雪婷. 滑移线场理论在正交切削过程中的研究现状［J］. 华南理工大学学报(自然科学版), 2019, 47(1):14-31.

SHI Yanhong, ZHAO Xianfeng, JIANG Xueting. Current Research on the Application of the Slip Line Field Theory in the Orthogonal Cutting Process［J］. Journal of South China University of Technology (Natural Science Edition), 2019:47(1):14-31.

［8］ZHANG H, LIU P, HU R. A Three-zone Model and Solution of Shear Angle in Orthogonal Machining［J］. Wear, 1991, 143(1):29-43.

［9］FANG N, DEWHURST P. Slip-line Modeling of Build-up Edge Formation in Machining［J］. International Journal of Mechanical Sciences, 2005, 47(4):1079-1098.

［10］KIYOTA H, ITOIGAWA F, ENDO S,et al. Analytical Approach for Optimization of Chamfered Cutting Tool Preparation Considering Build-up Edge Extrusion Behavior［J］. International Journal of Automotive Technology, 2013, 7(3):329-336.

［11］KARPAT Y, OZEL T. Analytical and Thermal Modeling of High-speed Machining with Chamfered Tools［J］. Journal of Manufacturing Science and Engineering, 2008, 130(1):011001.

［12］陈明君, 陈妮, 何宁, 等. 微铣削加工机理研究新进展［J］. 机械工程学报, 2014, 50(5):161-172.

CHEN Mingjun, CHEN Ni, HE Ning, et al. The Research Progress of Micro Milling in Machining Mechanism［J］. Journal of Mechanical Engineering, 2014, 50(5):161-172.

［13］罗翔, 黄燊华. 正交切削变形区的研究［J］. 广东工学院学报, 1989, 6(1):29-35.

LUO Xiang, HUANG Shenhua. A Study of Deformation Zone in Orthogonal Metal Cutting［J］. Journal of Guangdong Institute of Technology, 1989, 6(1):29-35.

［14］WALDORF D J, DEVOR R E, KAPOOR S G. A Slip-line Field for Ploughing during Orthogonal Cutting［J］. Journal of Manufacturing Science and Engineering, 1998, 120(4):693-699.

［15］FANG N. Slip-line Modeling of Machining with a Rounded-edge Tool—Part I:New Model and Theory［J］. Journal of Mechanics and Physics of Solids, 2003, 51(4):715-742.

［16］朱锟鹏, 李科选, 梅涛, 等. 微铣削力建模研究发展［J］. 机械工程学报, 2016, 52(17):20-34.

ZHU Kunpeng, LI Kexuan, MEI Tao, et al. Progress of Cutting Force Modeling in Micromilling［J］. Journal of Mechanical Engineering, 2016, 52(17):20-34.

［17］JIN X L, ALTINTAS Y. Slip-line Field of Micro-cutting Progress with Round Tool Edge Effect［J］. Journal of Material Processing Technology, 2011, 211(3):339-355.

［18］WAN M, WEN D Y, MA Y C,et al. On the Separation and Cutting Force Prediction in Micro Milling through Involving the Effect of Dead Metal Zone［J］. International Journal of Machine Tools and Manufacture, 2019, 146:103452.

［19］BARTARYA G, CHOUDHURY S. State of the Art in Hard Turning［J］. International Journal of Machine Tools and Manufacture, 2012, 53:1-14.

［20］WAN L, WANG D Z. Numerical Analysis of the Formation of the Dead Metal Zone with Different Tools in Orthogonal Cutting［J］. Simulation Modeling Practice and Theory, 2015, 56:1-15.

［21］AGMELL M, AHADI A, GUTNICHENKO O,et al. The Influence of Tool Micro-geometry on Stress Distribution in Turning Operations of AISI 4140 by FE Analysis［J］. International Journal of Advanced Manufacturing Technology, 2017, 89(9/12):3109-3122.

［22］FANG N. Tool-chip Friction in Machining with a Large Negative Rake Angle Tool［J］. Wear, 2005, 285(5):890-897.

［23］HU C, ZHUANG K J, WENG J,et al. Thermal-mechanical Model for Cutting with Negative Rake Angle Based on a Modified Slip-line Field Approach［J］. International Journal of Mechanical Sciences, 2019, 164:105167.

［24］OHBUCHI Y, OBIKAWA T. Finite Element Modeling of Chip Formation in the Domain of Negative Rake Angle Cutting［J］. Journal of Engineering Materials and Technology, 2003, 125(3):324-332.

［25］BAHI S, NOUARI M, MOUFKI A, et al. Hybrid Modeling of Sliding-sticking Zones at the Tool-chip Interface under Dry Machining and Tool Wear Analysis［J］. Wear, 2012, 286:45-54.

［26］THOMSEN E G, MACDONALD A, KOBAYASHI S. Flank Friction Studies with Carbide Tools Reveal Sublayer Plastic Flow［J］. Journal of Engineering for Industry, 1962, 84:53-62.

［27］KARPAT Y, OZEL T. An Integrated Analytical Model for Orthogonal Cutting with Chamfered Tools［J］. Transactions of NAMRI/SME, 2006, 34:9-16.

［28］HU C, ZHUANG K J, WENG J,et al. Cutting Temperature Prediction in Negative-rake-angle Machining with Chamfered Insert Based on a Modified Slip-line Field Approach［J］. International Journal of Mechanical Sciences, 2020, 167:105273.

［29］OZTURK S, ALTAN E. Slip-line Metal Cutting Model with Negative Rake Angle［J］. Journal of Brazilian Society of Mechanical Sciences and Engineering, 2012, 34(3):246-252.

［30］FATIMA A, MATIVENGA P T. A Review of Tool-chip Contact Length Models in Machining and Future Direction for Improvement［J］. Proceeding of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2013, 227(3):345-356.

［31］HILL R. On the Limits Set by Plastic Yielding to the Intensity of Singularities of Stress［J］. Journal of Mechanics and Physics of Solids, 1954, 2(4):278-285.

［32］FLUHRER J. DEFORM-3D Version 5.0 User’s Manual［J］. Scientific Forming Technologies Corporation, 2004.

［33］王子涛, 石广丰, 史国权. 负前角刀具正交切削的滞留特性及力学性能有限元仿真分析［J］. 刀具技术, 2018, 52(5):20-24.

WANG Zitao, SHI Guangfeng, SHI Guoquan. Finite Element Simulation Analysis of the Stagnant Characteristic and Mechanical Properties of the Orthogonal Cutting of Negative Rake Angle［J］. Tool Engineering, 2018, 52(5):20-24.

[1]	WANG Min. Cutting Parameter Optimization and Cutting Force Prediction for Fe-based Amorphous Alloy Spray-fused Coatings [J]. China Mechanical Engineering, 2017, 28(21): 2627-2631,2638.
[2]	Zhou Xin, Li Yingguang, Liu Hao, Liu Changqing. A Feature-based Cutting Force Fast Prediction and Evaluation for Complex Aircraft Structure Parts [J]. China Mechanical Engineering, 2015, 26(7): 886-891.
[3]	LING Ling, LI Xing-Xing, WANG Hua-Lin, HU Xu-Jin. Constitutive Model of Stainless Steel 0Cr18Ni9 and Its Influence on Cutting Force Prediction [J]. China Mechanical Engineering, 2012, 23(18): 2243-2248.
[4]	Liu Dexue;Ren Huaihui;Qin Xiaoqiong;Li Xudong. A Mechanical Model for Forming Process of Cone Bosses Based on Superimposed Slip-line Field [J]. J4, 2008, 19(23): 0-2897.

Prediction of Cutting Forces for Chamfered Inserts Based on Modified Slip-line Field Model#br#

基于修正滑移线场模型的倒棱刀具切削力预测

PDF

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 4

Recommended Articles

Metrics