Finite Element Simulation And Experimental Research Of Hard Cutting Process

Compared with grinding, hard-state cutting process has a very good process flexibility, economy and environmental protection, in this process, the hardness of the rough higher than HRC50 can be processed directly into work piece accurately. Thus, instead of grinding, hard-state cutting in today's machining has been increasingly widely used, and under certain conditions, hard-state cutting has become the first choice to replace grinding process. Therefore, in-depth studying of the mechanism and process optimization of the hard-state cutting has important significance.Based on describing research status at home and abroad, through combining theoretical analysis and experimental study, this paper start with the principle of metal cutting, using finite element simulation to do a more in-depth study of the process of PCBN tool hard-state cutting hardened steel GCr₁₅.By setting up reasonable boundary conditions, combining the grid adaptive control technology, two-dimensional finite element model of fully thermal coupled was established completely, cutting process of continuous chip was also studied. Using results in finite element simulation articles, the effects of cutter geometric parameters and cutting conditions take on cutting process was also researched in this paper. Under the use of reasonable material constitutive model and shear failure model, the finite element model of serrated chip formation process was set up in this paper, then using the finite element analysis consequence, influence of the cutting process caused by sharp edge and radius edge chamfering edge circle was analyzed.By combining with the technology of grid adaptive and delete, using the technology of quality amplification, three-dimensional finite element simulation model of hard cutting process was build. In order to verify the correctness of simulation results or not, this paper uses PCBN cutting tools of Sandvik for hardened bearing steel GCr₁₅ to conduct a series of cutting force and cutting temperature experiments in CA6140 lathe. Analyzed and compared by experiment and simulation, finite element emulates cutting forces, cutting temperature and surface residual stress, which have better accuracy. Using the simulation method can replace part of the experimental research, expand the application of finite element theory, promote the research of hard-state cutting mechanism and provide a useful reference for cutting tool geometry optimization and process.