Structural Optimization And Experimental Study Of The Inner-Cooled Tool

In this paper,the structure of the cutting tool is optimized to reduce the cutting temperature,the deformation of the cutting tool and break chip.The main research consists of the following aspects:(1)Designing and improving the structure of tool.Firstly,the 3D models of the tool are built.Then,the structure is simulated and analyzed by the finite element software.Finally,the carbide blade can meet the strength requirement when the hole diameter of carbide blade is 1mm.(2)The stress field and temperature field of the tool is studied and analyzed.For the pre-optimized tool and optimized tool,the stress field and temperature field of the tool is simulated and analyzed.For the stress field of the cutting tool,the stress of the optimized and inner-cooled tool has increased compared with the pre-optimized tool,but not much,almost negligible.For the temperature field,the temperature of the optimized tool is greatly reduced compared with the pre-optimized tool,and as the cutting parameter has increased,the cutting temperature did not increase much.Finally,the stress filed coupled by the cutting temperature is simulated.The simulation results show that the stress filed coupled by the cutting temperature of the optimized tool is less than the pre-optimized tool.(3)The deformation of the tool is analyzed.The deformation caused by stress?deformation caused by heat and coupled deformation are analyzed.For the deformation caused by stress,the deformation of the optimized tool has increased compared with the pre-optimized tool,but not much,almost negligible.For the deformation caused by heat,the deformation of the optimized and inner-cooled tool is greatly reduced compared with the pre-optimized tool.And as the cutting parameter has increased,the deformation did not increase much.For thermal-stress coupled analysis,the deformation of the optimized and inner-cooled tool is less than the pre-optimized tool.(4)The theory of cutting deformation is analyzed.Firstly,the area of cutting deformation is divided,and the deformation law is analyzed.Then,the types of the cutting chip are classified,and the mechanism of chip curling and chip breaking is analyzed.Finally,the two-dimensional and three-dimensional chip formation is simulated to prepare for the chip breaking experiment.(5)The Chip-breaking Performance of the optimized and inner-cooled tool is analyzed.Firstly,the laboratory table is built,and the cutting coolant is extrusive from the hole in the rake face of the tool.Then,aluminum?45 steel and stainless steel is cut by the optimized and inner-cooled tool.Finally,the experiment results indicate that the optimized and inner-cooled tool can break the chip.And the surface roughness Ra machined by the optimized tool is less than the pre-optimized tool.This indicates that the optimized and inner-cooled tool can make the deformation greatly reduced,which makes process accuracy and the surface quality of the workpiece greatly improved.