Simulation Research And Optimum Design Of Chip Breaking Of Translatable Grooved Blade

With the development of numerical tools, indexable grooving cutter inserts use becomes widespread, it has characters of a high life, high productivity, low cost, and is conducive to standardization and serialization features compared with normal grooving cutter.For50Mn materials,it will generate a lot of curling chips in the course of grooving in a small tank,if not promptly break chips and exclusion it would scratch the tank and affect tool life.Thus breaker question of grooving inserts becomes very important for50Mn because of its strong plastic and easy to strain hardening.This paper sets breaker chipbreaker way,and experiments how the size of chipbreakers influence chip breaking based on specialized cutting simulation software AdvantEdge. Simulating the impact of chipbreaker to the chip breakage and find out the relationship between the radius of curvature of chip fracture and the height and width of the chipbreaker units. In order to improve the life of the tool and find the best combination of cutting blade angle, using three-dimensional simulation of orthogonal cutting experiments and analysing cutting force, cutting temperature to optimize tool angle with poor analysis.First, summarize the factors affecting breaker condition and make mathematical breaker equation for this process in the form of grooving,deduceing the calculation model of the chip radius of curvature in chipbeaker units in the grooving process.Under no circumstances chipbeakers,experiment to validate50Mn’s chip breaking situation in processing and validate the AdvantEdge reliability comparing the experimental chip morphology and cutting force with software simulation’s.According to the deduced formula about the average curvature radius in grooving process,we design two-dimensional grooving inserts with different size of chipbreaker then make a simulation to prove the importance of chipbreaker to chip breakage.Complete the left grooving simulation experiment with different two-dimensional grooving inserts and find out the influence in curvature radius,the radius of curvature of the chip when breaking and the height and the groove width under a cutting parameters. In case there is chipbreakers units, followed by changes in cutting speed, feed experiment the chip breakage.After completing the simulation find out the right size of the chipbreaker, design blade main structure and draw three-dimensional model with NX software.Use univariate analysis method to simulate the impact on cutting force,cutting temperature before grooving blade front angle.Put out a orthogonal experimental method that can offer a suitable orthogonal to the four factors and four levels with grooving inserts to simulate three-dimensional grooving experiment. For the results of cutting force, cutting heat data using range analysis in order to locate and determine the impact of the main factors of the tool to the tangential direction of the cutting force, the radial direction of the cutting force, the maximum temperature and finally find the optimal parameter combination angle.The indexable grooving insert chip breakage simulation and angle optimization design can bring some ideas and values for chipbreaker design and grooving tool design.