Research Of High-temperature Alloy Machining Simulation Technologies

Metal cutting is a process with non-linear and heat-stress coupled.The heat is mostly from the distortion of chip and the friction at the tool-chip and tool-workpiece interface. The big heat source increases the temperature and causes the tool's abrasion. The cutting force denotes the cutting characters. The dynamic value affect the tool's abrasion and the quality of machined surface. So the research of cutting temperature and force is important.In this paper, Air China, Shenyang Liming Aero-Engine Group, developed a certain model of aero-engine power turbine disk slot mortise Broaching process, for the first time a multi-tooth broaching finite element model and for the first time simulation technique introduction of cooling simulation Broaching, by using finite element analysis method. The main work is to explore the temperature's distribution in tool area, chip area, and workpiece area and the force, to visualize the chip shape. Based on the finite element theory, the author provides the FE cutting model, uses the ABAQUS/Explicit software to simulate, according to the workpiece and tool's material changing with temperature, changing the friction type, defining the chip separating law, subdividing the local parts, setting the cooling parameter, etc. After the FEA the common rules between cutting temperature, force and cutting parameters are denoted. The chip shape are shown. Combined with literature results and simulation results were compared to verify the finite element simulation of serrated chip feasibility.