Research On Experiment And Finite Element Simulation Of Temperature Field For Cutting Of Al₂O₃Ceramic Used The Ording PDC Cutter

Cutting has been the mainstream status in the processing of engineering materials, it is theindispensable technology in the modern manufacturing processing. In traditional machining, forthe traditional cutter, a small number of cutting blades Involved in cutting at the same time, inorder to guarantee processing efficiency, cutting depth of a single cutting blade was big, resultingin relatively large cutting force, and the worse processing quality. While for the traditional wheel,abrasives were easy to fall off, grinding energy can be high, the ratio of normal force to tangentialforce was big, the grinding wheel was needed regular dressing, and was prone to clogging inprocessing plastic metals. Therefore, the orderly PDC cutter which has the advantages of bothtraditional cutter and grinding wheel was prepared by the project team.The ordered PDC cutter has a large number of cutting edges than the conventional cuttingtools, meanwhile it has a low ratio of normal to tangential grinding forces, desired geometries（e.g.,rake angles） and edge space among PDC fibers. Machining with the ordered PDC cutter isexpected to provide both good surface finish and high machining efficiency at the same time．Butcompared with the conventional diamond cutters and grinding wheel, cutting heat distributionwas much more complicated during the cutting process used the PDC cutter. The complexity ofthe heat distribution was the main reason for the heat damage of material and life of cutter.Therefor, research on3D finite element simulation and experiment of temperature field in surfacecutting used a new PDC cutter were carried out.The thesis analysed the present research on temperature in the cutting zone by domestic andforeign scholars, studied the generating mechanism of cutter heat, set up the cutting temperatureexperiment platform. On this base, research on experiment of temperature field in surface cuttingused a new PDC cutter was carried out. The effects of feed rate,cutting depth on cuttingtemperature were studied by single factor method. Cutting temperature increased with theincrease of the cutting depth, and cutting depth is the most important influence factor on thecutting temperature; Cutting temperature increased with the increase of the feed rate, but thetemperature growth decelerating trend was obvious.According to machining properties of materials, working conditions, on the basis of thetheory of thermal equilibrium of moving thermal source, the paper established the mathematicalmodel of temperature field of interrupted cutting used the PDC cutter through reasonablehypothesis. Base on ANSYS platform, simulations were performed for the temperaturedistribution in the tool-work interface and inside the Al₂O₃ceramic specimen using finite elementmethod, the simulation result intuitively revealed the morphological characteristics and changingtrends of3D temperature field. And a complete explanation of the changing trends was presented. Last, the validation and capability of the finite element model of the PDC cutter weredemonstrated by a satisfying agreement between the finite element simulation results andexperimental ones. That can predict and optimize the actual effect of cutting process, enrich andwiden the study in the field of surface cutting by the PDC cutter. The method played an importantrole in the industrialization of the PDC cutter and Engineering practice.