Machining Experiment Study And Simulation Study On Gray Iron HT250

As the heart of automobile,the quality of engine have an direct effect on usability.As the basic parts for assembling of each mechanism and system in the engine,the accuracy of manufacturing of cylinders which are made of Gray Iron HT250 have an important influence on the whole performance.It draws much attention that how to select appropriate cutting parameters to control cutting force and surface roughness.So,it not only has important practical significance,but also has certain theoretical significance.The paper takes the engine cylinder,which is made of HT250,as the research object.By the way of the combination of experiment and simulation,the paper analyzes the influence law of cutting parameters to cutting force and surface roughness by using the range analysis and using the robust design method,and gets the comprehensive optimal cutting parameters. This result can provide a reference for practical machining.The main study work of this paper contain three aspects as follow:First,in this paper,the three-dimensional milling is simplified to two dimensional orthogonal cutting model.And the finite element simulation of two dimensional cutting process is conducted by using ABAQUS.The chip formation and the cutting force waveform are got.The chip formation of the simulation model and the chip formation of the experiment is consistent,and the cutting force waveform of the simulation and experiment is consistent.It also concludes that the simulation model is reliable and accurate.The simulation results indicate that the cutting force reduces along with the increase of cutting speed,but not too much;and that the cutting force increase obviously with the increase of cutting depth.Second,the cutting experiment is conducted in the paper.Using orthogonal experiment method,the three factors and four levels orthogonal experiment table Li6(43) is established.According to the table,the cutting experiment is proceeded and receive the cutting force and surface roughness of each group.Then,using the extreme difference analysis method analyze the experiment data,and the optimal levels of each factors are received.Finally,this paper concludes the optimal parameters when taking the surface roughness as the index and the optimal parameters when taking the cutting force as the index.Finally, by using the robustness design method, the cutting parameters which influences the cutting force and surface roughness are optimized.In the end,this paper concludes the best group based on Taguchi robustness design method.And the best group is just the 15th group.Using this cutting parameters,smaller cutting force and better surface roughness are got while the metal removal rate remain high,and the steady is well.The purpose of optimization design is reached mainly.Through the study of the paper,this paper concludes the influence law of cutting parameters to cutting force and surface roughness by using the range analysis method and robustness design method. And it provides reliable theoretical basis and technical references for the engine cylinder milling.