20CrMo Material Cutting Constitutive Model And The Spiral Bevel Gear Dry Cutting Finite Element Simulation

The gear material20CrMo, which has the characteristics of good machinability and plastic deformation, is suitable for dry cutting. And the spiral bevel gear dry cutting technology is a efficient new type and green gear cutting method. It’s cutting principle、process parameters、cutting tool technology and so on is a hot research. The constitutive relational model and orthogonal cutting finite element simulation model of the gear material20CrMo have been studied in this paper. Different Cutting simulations about the spiral bevel gear on dry or wet Cutting conditions are also studied. And analysis is done on the results. The concrete contents are as follows.The Johnson-Cook model is used as a cutting thermo-viscoplastic constitutive relational model for the gear material20CrMo. The strain-hardening parameters for the model are obtained on the base of data from quasi static compression force test. And combine with the Oxley-Welsh cutting theory, the strain rate parameters and thermal softening effect parameters for the model are determined by analysis of the results from orthogonal cutting experiments. And based on these parameters, the cutting thermo-viscoplastic constitutive relational equation for the gear material20CrMo is established.With the sue of the software ABAQUS, a orthogonal cutting finite element simulation model for material20CrMo is established. The main cutting force and the cutting temperature field in the cutting process are analyzed. By comparison between simulation results and experimental data, it is showed the maximum cutting force relative error is within20%. It is also showed that the finite element cutting simulation established and the20CrMo’s material constitutive relational model are reasonable.Simple cutting simulation model for the spiral bevel gear is established. Different cutting simulation boundary conditions about the spiral bevel gear on dry or wet condition are determined. Comparative analysis on the main cutting force and the distribution temperature field in the different condition is done. It showed that the relative difference about the average main cutting force on dry cutting condition and wet cutting condition is small. And on dry condition, Local overheating phenomenon is happened between the cutting tool and the chip. Analysis about the machined surface node deformation on dry condition is also done. It shows that increasing the cutting speed can get good metal surface quality. Finally, research about coating friction reduction technology is done. The results show that the coating on the tool can effectively reduce cutting force and cutting temperature.