Finite Element Simulation Research On Tool Wear And Cutting Power Of Boring Machining

In recent years,as the main body of the national economy,the manufacturing industry has made great progress.The numerical control processing technology used in manufacturing has also been continuously upgrading to the direction of intelligentize,preciseness,and energy conservation to satify the requirements of modern production.In the manufacturing process of various products,boring technology as a key part of hole processing is widely used.In the boring process,the workpiece is fixed on the worktable by the clamp,and the worktable is controlled to move.The boring cutter blade is clamped on the cutter arbor and rotated by the spindle of the machine tool.Continuous contact friction between the tool and the workpiece causes the temperature of the contact area to rise,and the contact surface material of the tool and the workpiece in a high temperature environment for a long time deforms and falls off,which causes the tool to wear.After the tool is worn,the friction area increases,the cutting edge becomes blunt,and the surface load of the tool increases,which causes the cutting power to change.Studying the rules of tools wear and the variation trend of cutting power not only have significant meanings for extending tools life,improving production efficiency and product quality,but also promot the modernization development of CNC machine tools.In order to study the effect of tool wear on cutting power during the boring process,This article first carried out the tappet hole experiment of semi-precision boring diesel engine cylinder to extract the wear and main shaft power signal.The research shows that in the early stage of tool wear,the spindle power of the machine tool increases slowly as the wear intensifies,but when the average wear width of the tool flank reaches 0.36 mm,as the tool wear continues intensified,the power of machine tool spindles rose rapidly.The finite element simulation model of the worn tool is established based on the amount of tool wear obtained from the experiment in the way of equivalent contact area.The results show that the larger the radius of the cutting edge blunt circle,the greater the cutting power,and the simulated power is consistent with the experimental power.Therefore,changing the radius of the cutting edge blunt circle can characterize the degree of tool wear to a certain extent,which lays the foundation for the following research on tool wear and cutting power.Through the finite element simulation analysis of cutting processing,the influence of cutting speed,feed rate and back-engagement amount on cutting power was explored by single factor method.The study found that any increase of cutting data will lead the cutting power to rise.Then this paper conducts an orthogonal cutting simulation experiment.The simulation results show that the feed has the greatest influence on the cutting power and the cutting speed has the least influence.Finally,this paper research the effects of tool wear on cutting power while the cutting conditions are different.The study shows that under any cutting conditions,increased tool wear will lead to an increase in cutting power;And the best scheme of setting cutting cutting parameters which bring the slowest increase of cutting power are proposed,which provides a theoretical foundation for optimizing the production process and extending the service life of the tools.