Research On Finite Element Simulation Technology Of Dry Machining

Dry machining, as one of the main processing methods of green manufacturing, can avoid the negative environment impact of cutting fluid which is commonly used in traditional wet cutting. However, because of the lack of cutting fluid's cooling and lubricating, the surface quality of the work-piece becomes worse and the cutting tool becomes worn more seriously. As one of efficient method to study metal deformation and chip formation in machining, finite element simulation technology can better describe the mechanism of dry cutting, replace the traditional and time-consuming process of trial machining, and provide valuable data to the machining practice.In this dissertation, take 45 steel materials which commonly used in the field of machine manufacture as study object, the key technologies of dry machining finite element simulation– including material model, dynamic contact boundary treatment, finite element mesh and re-classified technology and tool-chip separation standards are studied deeply; based on finite element theory and rigid viscoplastic finite element modeling method, a three-dimensional dry machining finite element simulation model is established; Applying professional finite element software DEFROM, three-dimensional dry turning dynamic simulation are realized, and the chip formation, main cutting force changing curve, temperature field distribution and stress and strain distribution are presented in the simulation process; through simulating dry machining process under given condition, the relationship between cutting parameters, cutting tool geometric parameters and cutting temperature and main cutting force are analyzed, and influence curve of cutting parameters and cutting tool geometric parameters to cutting temperature and main cutting force are obtained, simulation results shows: the finite element simulation model can accurately reflect some of the physical properties of dry machining; finally, by compared theoretical calculations and simulation results, finite element simulation results and the calculated results are close, which shows that of the finite element simulation model is accurate in the given cutting parameter range, and can guide the actual cutting dry cutting within a certain range.The research results showed that dry machining simulation technology can predict the physical elements in the cutting process, can provide feasible method to study the mechanism of the dry machining, and have important theoretical and practical guidance for the actual dry cutting processing.