Face Milling Process Computer Simulation Analysis

Improving production efficiency and machining quality and reducing production costs have increasing become the primary objective for the manufacturers. With the development of the modern manufacturing technology, new materials, new tools and the constantly emergence of the new techniques and equipment, milling as one of the most widely applied methods in mechanical machining, it is necessary to carry on the milling process computer simulation analysis for improving efficiency and quality and optimizing the milling parameters.Milling has the characteristics of multiedges intermittent cutting and variable thickness machining, therefore, the mechanism of milling is more complex. Metal cutting theory, shear theory and the finite element method and so forth are involved in the thesis. A method combined experiment with theoretical model and computer analysis is adopted in it. Based on the principle of metal cutting, setting up a two-dimensional milling finite element thermal coupling model and 3-D milling machining finite element model. The factors of influencing milling force, through simulation, experimental verification and optimization model for the establishment have been studied in detail.On the basis of summarizing the status and trends of the milling process computer simulation analysis and, on the basis of carrying on the establishment and analysis of the milling geometric model by using the metal machining theory, and summarizing theoretical foundation of the milling process in the finite element simulation and several typical shear plane models, the main studies and innovations in the thesis are:(1) According to the software features of ABAQUS finite element analysis, the plastic deformation behavior of the chip in cutting prosess and how to achieve separation technology have been studied. Based on orthogonal cutting theory, the assumptions in the two-dimensional simulation of the milling is described. Both the milling tool and the workpiece geometric models in the ABAQUS software are established. The key technologies of the two-dimensional milling simulation is studied, finally, the two-dimensional orthogonal milling process is simulated ,its stress and strain, cutting force and the change trends of the temperature of both the workpiece and the tool are obtained, the simulation results are coincide with the general cutting theory.(2) Based on the 2D milling process simulation results and research and analyses above, the key technologies of realization of the 3D milling simulation, the assumptions of the milling process modeling, workpiece material, the pre-processing of the finite element simulation and the establishment of simplified model are studied. Through applying DEFORM-3D software, different types of milling states in four low speeds and seven medium speeds have been simulated. Gaining the stress, strain, milling force and temperatures of the workpiece in different milling states. The factors of influencing stress, strain, temperatures and cutting forces in milling process are analysed. According to the actual cutting conditions, the experimental is conducted in the first state for, through which the authenticity and reliability of the simulation is vertified, the reasons for the errors between the simulation results and the actual cutting results are analysed.(3) Based on the simulation conditions above, the optimization model of the main milling force and restrictive conditions have been established,using simplex method of the linear programming,the model is solved. The method provides a new approach for the studies on the milling optimization in the future.