Dem Simulation Of The Cutting Processes Of Chilled Cast Iron And CFRP

In manufacturing technology and science technology rapid development today, people often hope to use the inherent characteristics of the difficult-to-process materials and the advanced composite materials to achieve the process requirements of the complex, high strength, high hardness, good wear-resisting heat-resistant characteristics,etc.So,it is very important to study the cutting process of the difficult-to-process materials and the advanced composite materials.This paper mainly using particles discrete element method,and using discrete element software PFC2D(Particle Flow Code in 2 Dimension) to simulate the two-dimensional orthogonal cutting process of the difficult-to-process material chilled cast iron and the advanced composite material CFRP(Carbon Fiber Reinforced Plastics).The mainly research contents and the results are as follows:In the respect of two-dimensional orthogonal cutting process of a kind of brittle metal material Chilled cast iron, using the trial-and-error method and carrying on the multiple simulation to calibrate the model, and get the matching of physical and mechanical properties of discrete element model,and then, to establish the chilled cast iron 2d orthogonal cutting model. Adopting a single factor and orthogonal test method, in the study for different cutting speed v, cutting depth ap and rake angleγ0to affect the cutting force, and get the result of cutting force about 4400N~13900N. Analyses the cutting process,and getting the conclusion that with cutting speed, cutting depth increases, cutting force is also increasing.While rake angle on its influence is not big, but it affects the workpiece surface processing and smoothness and scraps forms, etc. And get the optimized process parameters: cutting speed v is about 18~24m/min,cutting depth ap is about 1~1.5mm,rake angleγ0 is about -3°~-6°.In the respect of two-dimensional orthogonal cutting process of a kind of composite material CFRP, using beam-particles unit to set up respectively fiber direction angleθ= 0°andθ= 90°two special one-way CFRP material PFC2D model.Also using the trial-and-error method and carrying on the multiple simulation to calibrate the model, and get the matching of physical and mechanical properties of discrete element model,and then, to establish their own 2d orthogonal cutting model. And also adopting a single factor and orthogonal test method, in the study for different cutting speed v, cutting depth ap and rake angleγ0to affect the cutting processes.Whileθ= 0°, get the result of cutting force about 770N~2320N. Analyses the cutting process,and getting the conclusion that with cutting speed, cutting depth increases, cutting force is also increasing,and the influence of cutting depth is bigger, but rake angle on its influence is not very significant.But,they different affect the quality of the workpiece surface processing ,etc.In order to improve the machining accuracy and processing efficiency,we use the optimized process parameters: cutting speed v is about 300m/min,cutting depth ap is about 1~1.5mm,rake angleγ0 is about -5°.Whileθ= 90°, get the result of cutting force about 480N~4320N. Analyses the cutting process,and getting the conclusion that with cutting speed, cutting depth increases, cutting force is also increasing,and the influence of cutting depth is bigger, but rake angle on its influence is not very significant.But,they different affect the quality of the workpiece surface processing and the internal organization,etc.In order to improve the machining accuracy and processing efficiency but not affect internal organizational structure,we use the optimized process parameters: cutting speed v is about 400m/min,cutting depth ap is about 1mm,rake angleγ0 is about 10°.