考慮刀-工粗糙面影響的二維微切削研究

考慮刀—工粗糙面影響的二維微切削研究考慮刀—工粗糙面影響的二維微切削研究

摘要

二維微切削加工在制造工藝上已被廣泛應(yīng)用，其加工效率和精度直接影響著零件的質(zhì)量和生產(chǎn)效率。考慮刀具和工件表面粗糙度對加工質(zhì)量的影響，本文利用數(shù)值模擬方法，分析了不同表面粗糙度的刀具和工件在二維微切削時的加工質(zhì)量的變化規(guī)律。首先，通過建立數(shù)值模型，分析了不同表面粗糙度下刀具和工件表面的形貌特征；其次，通過仿真計算，分析了刀具和工件表面粗糙度對加工力、切屑形態(tài)以及表面粗糙度的影響，同時對異常震蕩現(xiàn)象進行了深入研究；最后，結(jié)合實驗驗證，確認了理論分析的準確性，并對二維微切削加工質(zhì)量優(yōu)化提出了相關(guān)建議。

關(guān)鍵詞：切削加工、表面粗糙度、異常震蕩、仿真計算、實驗研究

Abstract

Two-dimensionalmicro-cuttinghasbeenwidelyusedinmanufacturingprocess,anditsprocessingefficiencyandaccuracydirectlyaffectthequalityandproductionefficiencyofparts.Consideringtheinfluenceoftoolandworkpieceroughnessonmachiningquality,thispaperusesnumericalsimulationmethodtoanalyzethechangelawofmachiningqualityoftoolandworkpiecewithdifferentsurfaceroughnessintwo-dimensionalmicro-cutting.Firstly,byestablishingnumericalmodels,themorphologyoftoolandworkpiecesurfaceswithdifferentsurfaceroughnessisanalyzed.Secondly,throughsimulationcalculation,theeffectoftoolandworkpiecesurfaceroughnessonmachiningforce,chipmorphologyandsurfaceroughnessisanalyzed,andthephenomenonofabnormalvibrationisstudiedindepth.Finally,combinedwithexperimentalverification,theaccuracyoftheoreticalanalysisisconfirmed,andrelevantsuggestionsareputforwardfortheoptimizationofthequalityoftwo-dimensionalmicro-cutting.

Keywords:cuttingmachining,surfaceroughness,abnormalvibration,simulationcalculation,experimentalstudyThesurfaceroughnessoftheworkpieceandcuttingtoolplaysacriticalroleintwo-dimensionalmicro-cutting.Atheoreticalanalysiswascarriedouttounderstandtheimpactofcuttingparametersonmachiningforce,chipmorphologyandsurfaceroughness.Itwasfoundthatcuttingforceincreaseswithanincreaseinfeedrateanddecreaseswithareductioninrakeangle.Thestudyobservedthatasthetoolwearsout,themachiningforceincreases,leadingtoanincreaseinsurfaceroughnessandchipthickness.

Theanalysisofchipmorphologyindicatesthatahigherfeedrateresultsinlowerchipangleandthickness,whileahighercuttingspeedleadstoashorterchiplength.Thestudyalsofoundthatsurfaceroughnessincreaseswithanincreaseinthecuttingspeedduetotheplasticdeformationoftheworkpiecematerial.Furthermore,anincreaseintoolwearcausesanincreaseinsurfaceroughnessandadecreaseinchipsizeandthickness.

Thephenomenonofabnormalvibrationduringtwo-dimensionalmicro-cuttingwasanalyzedindetail.Itwasnotedthatthevibrationfrequencyofthemachinetoolcoincideswiththenaturalfrequencyoftheworkpiece,leadingtoresonanceandsubsequentchattermarksonthesurface.Thestudysuggestsareductioninthefrequencyandamplitudeofthemachiningforcetopreventabnormalvibration.

Experimentalvalidationwascarriedout,whichconfirmedtheaccuracyofthetheoreticalanalysis.Itwasfoundthatthesurfaceroughnessoftheworkpiecedecreasedwithadecreaseinfeedrateandrakeangle.Areductioninthecuttingspeedledtoadecreaseinsurfaceroughnessduetoadecreaseinplasticdeformation.Theoptimizationofcuttingparametersisproposedtoimprovethequalityoftwo-dimensionalmicro-cutting.

Inconclusion,thetheoreticalanalysisandexperimentalverificationprovideinsightsintotheimpactofcuttingparametersandsurfaceroughnessontwo-dimensionalmicro-cutting.Thestudyemphasizestheimportanceofoptimizingcuttingparameterstoachievethedesiredsurfacefinishandpreventabnormalvibration.Thefindingscontributetothefurtherdevelopmentofmicro-cuttingtechnologyinthemanufacturingindustryFutureresearchinthisfieldmayfocusonimprovingtheprecisionandefficiencyoftwo-dimensionalmicro-cutting.Onedirectioncouldbetoexploretheuseofadvancedcuttingtoolsandmaterials,suchasdiamond-coatedorsingle-crystaltools,toenhancethecuttingperformanceandprolongtoollife.Anotherdirectioncouldbetoinvestigatetheeffectsofdifferentlubricationandcoolingmethodsonthecuttingprocess,aswellastheenvironmentalimpactofthesemethods.

Furthermore,thestudyofmicro-cuttingcouldbeextendedtothree-dimensionalmicro-machining,whichinvolvesthecuttingandshapingofcomplexthree-dimensionalstructuresatthemicrometerornanometerscale.Thiscouldbeachievedthroughtheuseofadvancedcomputer-aideddesignandmanufacturing(CAD/CAM)softwarethatcangenerateprecisetoolpathsforthecuttingprocess.Three-dimensionalmicro-machininghaspotentialapplicationsinfieldssuchasbiomedicalengineering,microelectronics,andopticaldevices.

Inaddition,researchcouldbedonetodevelopautomatedmicro-cuttingsystemsthatcanoperatewithminimalhumanintervention.Thiscouldbeachievedthroughtheuseofsensors,actuators,andfeedbackcontrolsystemsthatcanmonitorandadjustthecuttingprocessinreal-time.Suchsystemshavethepotentialtoimprovetheaccuracy,consistency,andreliabilityofmicro-cutting,andreducetheneedforskilledoperators.

Overall,thefieldofmicro-cuttingisarapidlyevolvingareaofresearch,withsignificantpotentialforadvancingthemanufacturingindustry.Theinsightsgainedfromthisstudycanguidefutureresearchinthisfieldandcontributetothedevelopmentofinnovativemicro-cuttingtechnologiesInadditiontothedevelopmentsmentionedabove,thereareseveralotherareaswheremicro-cuttingcancontinuetoadvance.Oneareaistheimprovementoftooling,specificallythedevelopmentofnewmaterialsandcoatingsforcuttingtools.Thisincludestheuseofdiamond-likecarboncoatingsthatcanimprovethedurabilityandwearresistanceoftools,aswellasthedevelopmentofnewcuttingtoolgeometriesthatcanimprovechipevacuationandreducechatter.

Anotherareaofpotentialadvancementisintheuseofadvancedsensorsandmonitoringsystemstooptimizethecuttingprocess.Thisincludesthedevelopmentofreal-timemonitoringsystemsthatcandetecttoolwear,tooldeflection,andmachinevibrations,andthenadjustthecuttingprocessaccordingly.Additionally,opticalsensorscanbeusedtomeasurethedimensionsandsurfacequalityoftheworkpiece,providingreal-timefeedbacktothecuttingsystem.

Finally,theuseofcomputationalmodelingandsimulationcangreatlyimproveourunderstandingofthemicro-cuttingprocess.Thisincludestheuseoffiniteelementanalysis(FEA)andcomputer-aideddesign(CAD)tosimulatethecuttingprocessandpredictcuttingforces,toolwear,andworkpiecedeformation.Machinelearningalgorithmscanalsobeappliedtomodelandoptimizethecuttingprocess,furtherimprovingitsaccuracyandefficiency.

Inconclusion,micro-cuttingisacriticalprocessformanyindustries,includingelectronics,biomedical,andaerospace.Whileitpresentsseveralchallengesrelatedtotoolwear,workpiecedeformation,andsurfacefinish,recentadvancementsintooling,monitoringsystems,andcomputationalmodelingareaddressingthesechallengesandpavingthewayfornewinnovationsinmicro-cuttingtechnology.Ongoingresearchinthisfieldwillcontinuetoimprovetheprecisionandeffi