Study On The Chip-breaking Mechanism And Prediction Of High Speed Cutting

High-speed machining (HSM) was an advanced and applied manufacturing technology, and became the developed direction of the metal cutting. But the process of manufacture has not achieved the idealization, because the exceptional break ratio of automatic production line or stand-alone is very highly, and the stability of manufacture system is bad, how to control the chip formation in high speed cutting and make the chip curl and break is the key problem to enhance the machining efficiency. Therefore, the thorough and systemic study of high speed cutting mechanism has a theory and basis value.Firstly, the instrument and chip sample which measures chip beaking strain is designed and made according to chip-breaking and sensor operating principle. Then, the change rules of chip breaking strain of 45 steel is measured. The influence of change regularity on the chip-breaking strain change with the cutting speed, feed rate and depths of cutting are carried through by the experiment. The result also validates the mathematical models which had obtained.Secondly, In order to study the change rule of chip breaking limits in high speed machining aluminum alloy LY12,high cutting experiments with PCD tool at ten cutting speeds are performed. Based on the above experiments, the mathematical model of the change rule between the cutting speed and the critical feed-rate and the mathematical model of the change rule between the cutting speed and the chip breaking region are built. And the experiment of chip–breaking strain of aluminum alloy style is made by the instrument, the influence of change regularity on the chip-breaking strain is analyzed by the results. The influence of change regularity on the chip-breaking strainwhich is effected by various kinds of factors in theory is also analyzed. The result also validates the mathematical models above.Lastly, the web-based machining chip-breaking predictive system of high speed machining is developed. The structure and function of predictive system are designed according to the requirement of production site. The predict technology of chip breaking is studied and the module of chip breaking predict is built up based on the chip breaking mathematics model of high cutting speed . Depending on the web-based client-server programming technology, by the J2EE technology flat roof, multiple users can access the system and predict chip breakage of high speed cutting anywhere through Internet/Intranet.