【摘要】：隨著現(xiàn)代工業(yè)技術(shù)的發(fā)展和產(chǎn)品零部件性能要求的提高,許多新型的難加工材料被研究者發(fā)現(xiàn)并生產(chǎn)了出來,因為新型的難加工材料具有較高的硬度,致使切削時較大的切削力,較高加工區(qū)域內(nèi)溫度的產(chǎn)生,這些問題導(dǎo)致了切削刀具的磨損情況加重,刀具使用壽命降低,且加工后的工件表面質(zhì)量不高,切削效率低,因此采用新的切削加工方法,提出降低硬切削刀具磨損和提高工件質(zhì)量的綠色制造新方法和理論,通過仿真實驗揭示切削參數(shù)對切削過程的影響,確定通電加熱切削的關(guān)鍵因素—切削電流,提出新的主切削力經(jīng)驗公式,有非常重要的學(xué)術(shù)價值和工程意義。本文基于Deform研究了(通電加熱切削條件下)刀具前角φ、切削速度V、進給量f、工件初始溫度T等對主切削力、接觸區(qū)溫度、刀具磨損量的影響,確定了YT726切削GCr15的最佳電流以及主切削力的經(jīng)驗公式。剖析了通電加熱切削降低工件切削難度的原理,通過對加熱電阻的分析,對比已經(jīng)存在的加熱電阻模型,選擇了一種較優(yōu)的電阻模型作為本課題的加熱電阻模型。除此外本課題還詳細介紹了材料的本構(gòu)模型、磨損模型、摩擦模型等相關(guān)理論知識,并根據(jù)實際情況選擇了仿真所需的相關(guān)模型及參數(shù)。經(jīng)過仿真試驗研究,論文得出了如下主要結(jié)論:(1)增大刀具前角、切削速度、工件初始溫度,主切削力反而降低;增加進給量,主切削力也逐漸增加。主要原因是刀具前角增加工件切削層的塑性變形減弱,接觸區(qū)的摩擦力降低;切削區(qū)溫度的增加,降低了加工區(qū)的強度,主切削力降低。(2)切削區(qū)溫度隨切削速度、進給量、工件初始溫度的升高而升高,隨刀具前角的增大而降低,最大的原因是刀具前角度數(shù)的增加,產(chǎn)生的切屑變形減弱,同時切削熱減少,所以切削區(qū)的溫度降低;隨著切削速度的增加,導(dǎo)致切削過程中產(chǎn)生的熱不能及時的隨切屑帶走,而且切削熱來不及向刀具傳遞,因而切削溫度升高。(3)刀具磨損隨刀具前角、切削速度、進給量的增加也逐漸加大,隨工件初始溫度升高而減少,最大原因是過高的溫度導(dǎo)致強度較高的刀具材料中的鈷元素流失,而工件材料中的鐵、碳元素向刀具材料擴散,降低了刀具材料的強度,加劇刀具磨損情況。(4)本文通過分析加熱電流對主切削力、切削溫度、刀具磨損量的影響,確定了YT726切削GCr15的最佳電流范圍為110-130A。(5)采用正交仿真實驗,通過SPSS統(tǒng)計軟件開展多元非線性回歸分析,得到了YT726切削GCr15的主切削力經(jīng)驗公式。
[Abstract]:With the development of modern industrial technology and the improvement of the performance requirements of product parts, many new types of hard-to-process materials have been discovered and produced by researchers, because the new hard-to-process materials have higher hardness. As a result of the larger cutting force and the higher temperature in the machining area, the wear of the cutting tool is aggravated, the service life of the cutting tool is reduced, and the surface quality of the workpiece is not high and the cutting efficiency is low. Therefore, a new green manufacturing method and theory to reduce the wear of hard cutting tools and improve the quality of workpiece are put forward by using a new cutting method, and the influence of cutting parameters on the cutting process is revealed by simulation experiments. It is of great academic value and engineering significance to determine the key factor of electrically heated cutting-cutting current and to put forward a new empirical formula of main cutting force. Based on Deform, the effects of cutting tool front angle 蠁, cutting speed V, feed rate f, workpiece initial temperature T on the main cutting force, contact zone temperature and tool wear are studied. The optimum current and the empirical formula of the main cutting force for YT726 cutting GCr15 are determined. This paper analyzes the principle of electric heating cutting to reduce the cutting difficulty of workpiece. Through the analysis of heating resistance and comparing the existing heating resistance model, a better resistance model is selected as the heating resistance model of this subject. In addition, the related theories of constitutive model, wear model and friction model are introduced in detail, and the relevant models and parameters for simulation are selected according to the actual situation. The main conclusions are as follows: (1) increasing the cutting speed, the initial temperature of the workpiece and the main cutting force decrease, and the main cutting force increases with the increase of feed rate. The main reasons are that the plastic deformation of the cutting layer decreases and the friction in the contact area decreases with the increase of the cutting front angle, and the strength of the machining zone decreases with the increase of the temperature in the cutting zone. (2) the temperature of the cutting zone decreases with the cutting speed and the feed rate. The increase of the initial temperature of the workpiece decreases with the increase of the front angle of the cutting tool. The biggest reason is that the chip deformation decreases and the cutting heat decreases with the increase of the number of the front angles of the cutting tool, so the temperature of the cutting zone decreases. With the increase of cutting speed, the heat produced in cutting process can not be taken away with chip in time, and the cutting heat can not be transferred to the tool, so the cutting temperature increases. (3) the tool wear increases with the cutting tool front angle and cutting speed. The increase of feed rate gradually increases and decreases with the increase of the initial temperature of the workpiece. The biggest reason is that the high temperature causes the loss of cobalt element in the high strength cutting tool material, while the iron and carbon elements in the workpiece material diffuse to the tool material. (4) by analyzing the influence of heating current on the main cutting force, cutting temperature and tool wear, the optimum current range of YT726 cutting GCr15 is determined to be 110-130 A. (5) orthogonal simulation experiment is used. The empirical formula of the main cutting force of YT726 cutting GCr15 is obtained by multivariate nonlinear regression analysis with SPSS statistical software.
【學(xué)位授予單位】：西華大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG506

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