Analysis Of Cutting Mechanism Considering Material Hardness And Development Of Cutting Simulation Platform

The research on metal cutting mechanism has always been the key and difficult point in mechanical manufacturing industry.With the appearance and development of advanced manufacturing technology,such as high speed cutting and micro cutting,the metal cutting technology has renewed vitality.Furthermore,due to the rapid development of computer technology,numerical simulation has become an important method and means to analyze the metal cutting process and optimize the process parameters.Based on numerical simulation technology,this thesis aims to explore the metal cutting mechanism from material hardness and to develop the metal cutting simulation platform.To sum up,the main research contents are as follows.(1)The existed cutting simulation model is improved by considering the ploughing in metal cutting process,and the viscous angle and ploughing depth of hardened steel AISI D2 are obtained.A single sawtooth chip produced by high speed machining is simulated,then the stress,strain rate,material damage and temperature field are analyzed.Besides,the experiment of ball end milling is carried out to verify the simulation model.(2)The characterization of sawtooth chip is summarized in terms of machining mechanism,geometry morphology and physical properties.The effect of material parameters on chip formation is analyzed by single factor method,and the influence of the constitutive parameters on the material machinability is obtained.This will provide reference and guidance for the prediction of the material parameters in different hardness values and the hardness values of material according to the constitutive parameters,as well as the analysis of the differences between the different materials.(3)What's more,the dynamic constitutive model considering material hardness are established,and that of AISI H13 and AISI D2 are acquired.Besides.A orthogonal cutting simulation model considering the change of material hardness is established.The machining mechanism of variable hardness material AISI H13 is preliminarily explored,and the change of cutting force,cutting temperature and material damage during are achieved,and the influence of cutting manner and hardness gradient on cutting process is analyzed as well.This will provide theoretical basis and reference for the research on cutting mechanism of heterogeneous materials.(4)Based on Python language,the metal cutting simulation platform is developed on the ABAQUS software.In this paper,the development process is introduced in detail.For instance,the kernel program is illustrated with the example of the tool parameterization program.The GUI plug-in program is explained by the example of the simulation program of the orthogonal cutting process.In the end,metal cutting simulation platform is described with examples,including the parametric modeling process of the variable hardness cutting simulation module,the oblique cutting simulation module and the vertical milling simulation module.The platform will provide a digital analysis tool for computer aided manufacturing.