Research And Application Of Metal Cutting Modeling Technology Based On Finite Element Method

Metal cutting processing in mechanical manufacturing industry takes an important position; it has a far-reaching influence to the country's economic and technological development. The essence of metal cutting processing is that under the interaction between tool and workpiece, tools are used to cut off the redundant metal of workpiece in order to acquire the shape, precision and surface quality met the workpiece requirements. This process will be accompanied by various phenomena,such as cutting deformation, cutting force and cutting heat, tool wear and durability etc., and these phenomena influence seriously production, the quality of the products and the cost of production. Thus, metal cutting process is a very complicated process.In order to improve the machining quality, production efficiency and economic benefit, every country and enterprise in the world had invested a lot of human, material and financial resources for research and exploration of metal cutting process.However, the traditional research method must perform a lot of cutting experiments, which will lead to increase research cost, prolong research cycle, and more hinder seriously the development of cutting technology. With the development of science and technology, a number of new materials and new technologies emerge. Therefore, a new research method is asked to replace traditional research methods. It is the numerical simulation, which uses computer simulation to replace practical cutting experimental, and could study metal cutting more effectively. Meanwhile, it provides the basis for optimizing cutting parameters and adaptive control.This paper makes a explorative study on the finite element method of metal cutting, and puts forward a corresponding method, the validity and rationality of which is validated by cutting experiment. This method can quickly and effectively forecast metal cutting result, at the same time, shorten research cycle, and improve the work efficiency. This main contents are as follows:Firstly, based on the metal cutting theory and the predecessor's research achievements, it is analyzed that metal cutting deformation, cutting force and contacting friction between tool and chip etc., and nonlinear finite element theory, elastic-plastic finite element theory and thermal-stress coupling theory are expounded. That provides theoretical basis for the late finite element simulation.Secondly, base on analyzing the key technologies of finite element simulation, the two-dimensional orthogonal cutting model is built. In the meanwhile, the finite element method used in the paper is presented. Thereafter, a cutting experiment is designed, and its reasonability is validated by comparing simulation results and experimental data.Finally, the influence of chamfer edge tool is studied in cutting process of stainless steel AISI 316. Stainless steel belongs to difficult-to-machine materials, and chamfer edge tools is often used in order to improve the machining performance. By finite element simulation, the process of cutting stainless steel using chamfer edge tools with different chamfer widths and chamfer angles is studied. The following results can be obtained:cutting force and maximum residual tensile stress increase as chamfer width and chamfer angle increase; and cutting temperature slightly decreases, which can be neglected. The study results provide the theory basis for optimization design of chamfer edge tool structure.