| AISI 201 has been widely used in the field of equipment manufacturing due to its high hardness,high toughness,high plasticity,low thermal conductivity and good comprehensive mechanical properties.In the process of cutting AISI 201,the tool is easy to wear,which leads to its short life,increases the production cost and reduces the production efficiency.Many studies show that the reasonable tool structure design can improve the cutting performance of the tool.Experience design,cutting design and optimal design based on performance are the main methods of tool design.This is especially true for the near field design of the cutting edge of the tool rake face.Based on the combination of temperature field and wear field of rake face,an innovative design method of micro groove near cutting edge was proposed to design and fabricate innovative micro groove tool for cutting AISI 201,using the comparative research method of theoretical analysis,simulation research and cutting experiment.The change rule of cutting force,cutting temperature,cutting energy and machined surface quality of micro groove tool was analyzed.The tool wear mechanism and its monitoring and identification were studied,and the cutting performance of the tool was comprehensively evaluated,so as to reduce the cutting force and cutting temperature and improve the service life of the tool.The main research contents were as follows:The design method of micro groove near the cutting edge of rake face based on the temperature field and wear field of the tool is established.Taking Deform 3D as the numerical simulation platform,the finite element numerical simulation of the original turning tool cutting was carried out.After the simulation,the temperature field data was derived in the postprocessing module,and the reasonable temperature data was screened by Matlab.The data was imported into the UG NX 8.5 platform through the secondary interface.Using the powerful surface modeling of UG,the temperature field mesh surface was generated,and the initial model of micro groove tool was established,taking the main size parameters of the cutting wear field and the initial micro groove as variables.The cutting simulation experiment was designed to optimize the micro groove,determined the micro groove structure of the tool,checked the strength of the micro groove edge area,and prepared innovative micro groove tools.The cutting mechanism of micro groove tool is analyzed.Based on the analysis of the geometric relationship of the plastic deformation shear plane and the tool chip balance force system of the micro grooving tool,in order to further analyze the cutting performance change of the micro grooving tool in the following chapters,the cutting experiment was designed to analyze the stress and strain in the shear zone of AISI 201 under different cutting parameters,and the cutting equation of micro grooving tool was obtained.It was found that the micro grooving tool changed the balance of tool-chip force system and greatly increased the shear angle.The Rubenstein model was used to analyze the internal and external friction lengths of tool chip contact.The contact and friction behavior between the tool rake face and the chip were studied,and the mechanism of the force change of the tool was analyzed.It was found that the micro groove changed the tool-chip contact area,greatly reduces the tool-chip contact length and the contact length of the internal and external friction areas,and reduced the friction between the tool and chip.The cutting energy of micro groove tool and the surface quality of workpiece are studied.By the research methods of combining theoretical analysis,simulation and cutting experiment,different experimental schemes were designed to analyze the cutting performance of micro groove tool under different cutting parameters.The cutting force,temperature,cutting specific energy,work-piece surface roughness and surface hardness of micro groove tool and original tool were compared.Compared with the original tool,it was found that under the same cutting conditions,the three-dimensional cutting force and cutting temperature of the micro groove tool were greatly reduced,the cutting specific energy was lower,the surface roughness of the workpiece was smaller,and the hardening degree of the work-piece was lower.The correlation analysis between specific energy and work-piece surface quality showed that the specific energy of micro groove tool was lower than that of the original tool to obtain the same workpiece surface quality.In order to obtain good surface quality,it was necessary to select the cutting parameters at a lower specific energy.The wear mechanism and wear state identification of micro groove tool are studied by cutting durability experiment.The results showed that under the same cutting conditions,the three-dimensional cutting force of the micro groove tool was less,the cutting energy consumption was lower,and the abrasive wear,adhesive wear and oxidation wear were less.The cutting time of the original tool was 16 min,while that of the micro-groove tool was 82 min.So the cutting durability was greatly improved.A tool wear state recognition method based on deep learning was established.Through vibration signal acquisition and ultra depth of field microscope tool wear observation,the correlation between tool wear and tool vibration signal was constructed,and wear state data samples for model training were formed.The trained VGGNet network model was used for the intelligent recognition of tool wear state,which showed that the method can effectively realize the recognition of tool wear state,and the recognition accuracy reached 0.9551.The above research showed that the micro groove tool increased the shear angle,changed the tool-chip contact model,reduced the material plastic deformation,cutting force,temperature,cutting energy input of the tool,and the tool wear greatly.The service life of cutting tool is improved significantly.The effectiveness of the new design method based on the combination of the rake face temperature field and wear field was verified. |
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