| Forming tool as a professional cutting tool,has the characteristics of high production efficiency,stable processing quality and long service life.It is widely used in production and processing of large batch forming parts.Designing profile of forming tool is the key of tool design process,so to get accurate tool edge shape,a new profile design method is used in this paper.The design and optimization of tool is to improve the machining accuracy,therefore this article bases on the design principle of forming turning tool and the actual machining process to conduct in-depth analysis on machining precision of the tool.The research contents mainly include:(1)The development of the forming tool at home and abroad,the types and characteristics of the forming cutter and turning finite element simulation technology and related knowledge were briefly summarized.(2)Traditional design methods of forming tool were introduced and its defects were analyzed,then a high-precision truncating method was put forward to design tool profile.A three dimensional model of round-body copying turning tool was established combination to the subject.The analysis and research of the cutting force of turning was carried out,then applying simulation method or experiment method to get the cutting force of the tool was proposed based on the characteristic of the cutting edge of the forming tool.It laid the foundation of the researching the cutting performance of forming tool afterwards.(3)The turning finite element simulation models of round-body copying turning tool were established based on the soft of AdvantEge FEM,then the cutting force,the cutting temperature and the cutting stress of the turning process were analyzed and researched.On the basis of 3D turning FEM simulation model,the rake angle and the relief angle of forming turning tool were optimized on the objective of the main cutting force.In order to study the vibration property of the tool,a modal analysis of the turning tool was carried out on the platform of the ANSYS workbench.(4)The hyperbolic error which appeared when the forming tool machining conical surface was studied in this paper,then pointed out that there was no error when adopted truncate method to design forming tool.Furthermore a mathematical model of the profile of turning tool in the normal plane was founded.Considering the actual situation of processing of the tool,effects including tool manufacture tool vibration and the steady state of deformation and other factors on the cutting machining accuracy of forming tool were analyzed in this article and the turning experiment of round-body copying turning tool was carried out.The optimization approach was proposed in the paper,which combines parametric modeling,FEM simulation and numerical optimization algorithms,meanwhile it can be a reference for other tool structure optimization. |
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