| Deep hole parts have been widely used in weapon equipment,rail transit,engineering machinery and other fields.The hole processing quality has a direct impact on the comprehensive performance and service life of products.Generally,drilling,boring,reaming and other simple machining processes can be used for hole processing.But for deep hole parts with semi-closed and weak rigid structure,if still used the traditional simple manufacturing process,it is difficult to considering both machining accuracy and efficiency.Therefore,using deep hole boring equipment and special boring and rolling tool to process deep hole parts,The workpiece only needs to be clamped once,the equipment can complete rough boring,fine boring and rolling,The machining accuracy and efficiency can be effectively improved.But the chip breaking performance of boring insert has a great influence on the rolling process and workpiece surface quality.Therefore,research on the chip breaking groove structure of deep hole boring insert on chip breaking performance and optimizing groove structure,It is an important research topic to improve the quality and efficiency of deep hole boring.For this reason,this paper focuses on the chip breaking process of deep hole boring insert,based on the chip breaking theory of chip breaking groove and particle swarm optimization algorithm,Three coordinate profilometer,AdvantEdge cutting simulation software,UG NX10.0,Auto CAD2016 and other tools.The chip breaking mechanism of different groove elements is analyzed and the influence of groove parameters on chip breaking performance,The influence of groove parameters on chip curl radius and cutting force was explored,based on the three important groove parameters,the chip breaking groove was optimized,in order to improve the chip breaking performance of the insert.The specific research work is as follows:(1)Research on chip breaking mechanism of chip breaker.The groove types of commercial inserts are divided into three basic groove units,and the chip breaking mechanism is analyzed one by one,The equivalent groove width and chip curl radius under different cutting conditions are obtained;The influence of groove parameters on chip breaking performance and cutting performance is explored,it provides a theoretical basis for the structural design optimization of chip breaker.(2)Experimental and Simulation Study on chip breaking performance of insert.Firstly,the groove parameters of four kinds of inserts were measured by profilometer,the two-dimensional and three-dimensional models of inserts were established;the turning experiment of 45 steel was carried out,the chip breaking performance and cutting performance of four kinds of inserts were compared and analyzed,the influence of groove parameters on chip breaking performance is discussed,a suitable groove structure to be optimized is selected;using the established insert model,turning simulation is carried out by using advantedge software,The simulation results are compared with the experimental results,verify the effectiveness of the simulation model(3)The structure of chip breaking groove is optimized.The influence of six groove parameters on chip curl radius and cutting force is analyzed by cutting simulation,three groove parameters with great influence are determined,the regression model of chip curl radius and main cutting force is established by response surface method,the optimized groove parameters are obtained by particle swarm optimization;two-dimensional and three-dimensional models of the optimized insert were established,the turning simulation experiment is carried out,the simulation results before and after optimization were compared,to verify the rationality of the structure optimization of chip breaker.In summary,the research in this paper will have a good theoretical significance for the structural design optimization of chip breaking groove of deep hole boring insert,and is expected to further improve the processing quality and efficiency of deep hole parts. |
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