The Estimation Method Tool-chip Friction Coefficient FEM For The Influence Of Cutting Parameters And For Residual Stress

The residual stress generated in metal cutting process seriously effect performance,so the research has been attracting attention all the time. Precisely predicting thedistribution of residual stress can guide practical processing and has a great value ofengineering application. When the cutting tool and workpiece is given, the cuttingparameters are the important factors which infulented the distribution, so explore theinfluence rule can help reasonably select the cutting parameters, and control the residualstress. The finite element simulations was adopted to study the influence of the cuttingspeed and feed on the residual stress, considering the infulence of tool-chip, and prove theresult by means of experiments. The main research contents are:Frist，The mechanism of residual stress were studied, and the residual stresssimulation models provided by the AdvantEdge software were used, cutting tool,workpiece and the cutting condition setting were introduced, and the influence of thecutting speed, feeding on residual stress were preliminary researched, and the influence ofthe tool-chip friction coefficient on simulation accuracy.A new tool-chip friction coefficient estimate approach was presented. Frist, a newmathematical model of cutting forces, the cutting speed, feed and tool-chip frictioncoefficient was established based on the simulation results of Advant Edge, and it wasreversed when the cutting forces are measured in orthogonal turning1045steelexperiment.The residual stress of the machined workpiece was texted by the X-ray diffraction,and comparing the simulation residual stress distribution of the friction coefficient incalculation, average coulomb friction coefficient, the default friction coefficient withexperimental result; it turns out the distribution of residual stresses in the frictioncoefficient of calculation approaches to experimental result.Finally, the simulation models were used to study the influence of the cutting speedand feed on the distribution of the residual stress, and the results were explained throughthe changes of the cutting force and cutting temperature which cutting speed and feed wascaused, according to the analysises of the results, the cutting parameters were selectedwithin the scope.We can know tool-chip friction coefficient estimated accurtly can improve theprecision, select cutting parameters reasonably can control the distribution of residualstress.