Research On Designing Of Turning Inserts With Three-dimension Complex Groove Based On Cellular Automata And Its Chip Breaking

In tuning, how to control chip forming, regularly curling and breaking is a key to increase the efficiency of the automatic production system. Chip breaking can be realized in many ways, but chip-breaking groove is more widely used at present. A right groove, with which chip can be broken reliably, decreases the abnormal outage rate of machine for chip breaking failure and ensures normal cutting. So a better and more appropriate design for groove is important in turning.It is widely known that groove design is terribly complex since chip breaking is affected by many factors. This paper designs groove with Cellular Automata (CA) that is a mathematic model used to solve problems in complex systems.Firstly, CA model of groove curves was established for common use in typical section. Based on the Cowell model of chip flowing angle and equivalent groove parameters, the mathematic model for equivalent width was built and the values of equivalent width applicable to different workpiece materials were computed, then cell space was settled. The evolvement rules fitted for each curve were given for five different curves according to chip curling and breaking theory. The dynamic evolution of CA models was realized with MATLAB and geometric parameters of every groove curve in any section perpendicular to cutting edge is gotten as a result. All above provided exact data for groove designing and substituted for the traditional method deriving from experience and experiment.Secondly, this paper also put forward a merging rule and an algorithm of the three-dimension (3D) complex groove composed of many sections based on CA model of 2D groove curve. The new 3D complex groove insert with which chip breaking can be controlled was developed and researched. The insert part was designed and created with Pro/Engineer. The parametric designing system was developed with the Pro/Toolkit and VC++ in order to minimize designing procedures, reduce both mental and physical work in part creating and enhance the market competition of inserts, compared with conventional Pro/Engineer.Thirdly, the new 2D and 3D grooved inserts were processed and the chip- breaking experiment was done. The 2D chip-breaking experiment indicates that geometrical parameters from CA model were reasonable. The 3D chip-breaking experiment indicates that the chip-breaking range was bigger and chip shape was better than other same type products, which fulfilled the expected chip shape and chip breaking range. The experiment results also prove that CA can be used in 3D complex groove inserts designing.Finally, the BP neural net for the pre-estimated chip-breaking range was established to save the use of workpiece and experimental work and pave a theoretical way for selecting proper cutting parameters in practice.