Simulation And Experimental Study Of The Turning Of A Large Long Lead Spiral Drum

Currently,weapons and equipment are rapidly updating and upgrading.The non-linkage ammunition feeding system has seen rapid development and is gradually becoming the preferred feeding method for modern weapons and equipment due to its special helical groove structure,which enables efficient ammunition feeding.ZL205 A,a difficult-to-process material with unique physical and mechanical properties,excellent toughness,and corrosion resistance,is used as the forming material for the helical drum.The main research approach of this article is how to efficiently and accurately process large castings with complex structures and special materials while ensuring precision and high quality.Based on the fundamental principles of conjugate surfaces,the meshing conditions of conjugate curves,the properties and processing principles of helical surfaces,the geometric model of the helical drum is established using UG.The cutting finite element model of the helical drum is then created using DEFORM-3D by applying the criteria for chip separation,adaptive meshing techniques,the comprehensive applicability of J-C constitutive models,reasonable planning of tool motion trajectories,and accurate setting of other relevant parameters.A finite element simulation analysis of the helical drum turning process is carried out using DEFORM-3D.Using the single-factor test method,three-factor four-level orthogonal test method,and range analysis method,the influence of the main tool geometry angles(rake angle,clearance angle,and cutting edge radius)and cutting parameters(feed rate,cutting depth,and cutting speed)on cutting performance is analyzed,and the theoretical optimal tool geometry angles and cutting parameter values are determined.The scientific accuracy of the simulation optimization results is verified through turning experiments,where data is collected using a CW6163 C horizontal lathe and a KISTLER piezoelectric force sensor.The collected data is then filtered,amplified,calculated,and analyzed,and the results are compared with those obtained from the simulation experiments.The simulation results are close to the experimental results,indicating high reliability.The results show that DEFORM-3D can accurately simulate the turning process and provide theoretical support for optimizing the main tool geometry angles and cutting parameters.A predictive model for cutting force and tool tip temperature based on exponential functions was established,and multiple linear regression analysis and significance testing were conducted.The results showed that the predictive models for each cutting force and tool tip temperature had good fitting degrees.The various objective functions were reasonably constrained with the aim of reducing cutting force,decreasing tool tip temperature,and improving metal cutting efficiency.The genetic algorithm in the Optimization Tool toolbox of MATLAB software was used for multiobjective optimization of cutting parameters.The optimization results of the relationships among cutting force,tool tip temperature,and material removal rate were obtained,and the relationships between genetic generations and average distances between individuals,as well as 150 ideal Pareto optimal solution sets.The results indicated that using a multi-objective genetic algorithm to optimize cutting parameters can provide effective guidance and help for cutting processing.