Design Of The Geometrical Parameters Of The Chip Breaker For Rough Machining Based On Numerical Simulation

Cutting tool technology is an important part of modern machining technology,which plays a very important role in the manufacturing industry.The development and innovation of cutting tool technology promote manufacturing industry.The chip breaker,as an important part of the cutting tool,could enhance the cutting performance of cutting tool and improve the chip control.In this paper,the geometrical parameters of chip breaker are designed based on the Finite Element Method(FEM).The main work summarized as follows:(1)A 2D finite element model of orthogonal cutting has been built and the cutting experiments have been carried out.The cutting forces and chip morphology have been compared with the experimental results.The average error of cutting forces is less than 10%.The simulation results show good agreement with the experiment results.(2)The optimization methodology of cutting edge geometric parameters has been proposed.The tool stress and chip curl radius are select as the evaluation index to optimize the geometrical parameters of rounded edge and chamfered edge.It finds that small(large)rake angle combined with small(large)chamfer length is more reasonable to reduce the tool stress.The optimal geometric parameters of chamfered edge for rough machining Fe-Cr-Ni stainless steel are that the rake angle is from 16° to 17°,and the related length of land is from 60?m to 70?m.(3)The geometrical parameters of chip breaker are designed after the optimal design of chamfered cutting edge.The parameters of straight flat type chip groove are divided into four parts and the influence of these parameters on chip breaking has been analyzed.It finds that the most important parameters are the length of the rake face and flat face,followed by angle of groove backwall,the least important parameter should be the length of groove backwall.(4)The optimal combination of rake face length and flat face length is determined based on the design premise of chip breaking performance.For rough machining Fe-Cr-Ni stainless steel,the optimal lengths of rake face are 0.8mm,1.0mm,and 1.2mm,combining with the lengths of flat face 0.8mm,0.5mm,and 0.2mm,respectively.The normalized index considering the tool stress and chip curl radius is calculated by the Min-max normalization.The optimal angle of groove backwall is from 25° to 30°.The influence of angle of groove backwall on tool stress and chip curl radius is analyzed.The chip curl radius of simulation results is compared with the theoretical value,and the average error is about 10%.(5)Compared with the commercial chip breaker,the groove designed in this paper could effectively reduce the tool stress.