Simulation Of The Tube Roll-Cutting Process And Key Equipment Design

The cutting machine is important equipment in producing and using the tube. There are a few problems in the tube cutting methods which are used normally. It is difficult to make cutting quality good because tube is hollow shape. For the sake of improving cutting quality, the tube roll-cutting is widely used in recent years. It uses three dishing blades to wheel on the tube exterior surface and cut into the material gradually. In the whole process, the blades turn around the tube axis and spins about their own axis as well. Because the blade stroke in the radial direction is just a little larger than the tube wall thickness, the size of the cutting tool can be reduced. In the roll-cutting process, there is no noise and no burrs exist. The tube roll-cutting not only samplifies the product process, but also improves the working environment.The roll-cutting principle and schematic arrangement of the roll-cutting machine is demonstrater in the paper. According the roll-cutting machine's principle of work and the structure feature, the machine has been simplified. The roll-cutting system transverse vibration mechanics model has been established using the flexibility method of correlates. The natural frequency and first mode shape has been calculated. The imbalanced dynamic response caused by the mass bias with and without the damping has been solved. The response diagrams of curves have been drawn up. The rotor mass bias moment and the system damping ratio to the system dynamic response influence rule has been discussed.The large plastice deformation and ductile fracture happens in the roll-cutting process. It's very difficult to calculate the cutting process. This paper has made the theoretical analysis using the theory of wedge indentation of ductile material. The equations of the cutting force and contacted area have been obtained.For the sake of taking the advantage of the roll-cutting machine and removing some bed factors, the process of roll-cutting has been simulated on the basis of the principle of large deformation FEM by using DEFORMTM 3D program. The relationship between the cutting force and cutting depth has been demonstrated. The influences of process parameters on the cutting force, cutting quality and balde stress have been found out. The reasonable parameters match has been obtained. The database of the effect of process parameters on the roll-cutting process has been founded for the convenience of inquiry.The author has designded an experiment system which is used to measure the roll-cutting force and feed speed. The curves for the cutting force with cutting depth, feed speed with the cutting depth and the dimension of fraction have been obtained using the experimental method. The results of the FE analysis are in agreement with the results of the experiment, through comparison between the simulated and measured result. It verified the validity of the simulation. By studying the cutting force, the effects of process parameters on the cutting force can be obtained. It is the foundation of the blade stress analysis.The theoretical analysis and experimental research indicate that there are many complicated problem involved in the roll-cutting process and researches on these problems can reveal mechanisms of deformation and balde failure. It is helpful to get a good cutting quality and improve the blade stress state. Also, it is useful to propose new cutting process. Of course, it is required that much profound and detail work of roll-cutting process will be done in the future.