Cutting Force Modeling Simulation And Experimental Study Of Linear Fly Cutting Process

Flying cutting is an important method of metal cutting research,it is simple to manufacture and has a short production cycle and low cost,it is commonly used to simulate hobbing and worm processing.Gear hobbing machining has good technical characteristics such as high efhis ficiency and good versatility,it is commonly used in the gear processing technology in our country,therefore the research has an important significance.In this paper,the linear flying cuttitong model similar to gear hobbing that regarding cutting force as respondent is established aimed at poor universality,high cost and imprecision in the physics simulation model field of hobbing cutting force,the cuting force in the flying cutting process is analyzed from three aspects on analytical modeling,finite element simulation and experiment,it has an important theoretical value and practical significance on hobbing cutting mechanism reserach.In this paper,cutting edge engagement to cutting is given full consideration,the three most representative cutting edges that top edge,side edge and arc edge between the two transition participating in cutting at the same time is stduied,the main research contents are as follows:First,the flying cutting process is described,the instantaneous cutting layer characteristics of flying cutter at the angle equal to is analyzed,cutting layer is discreted along the axis,the instantaneous cutting force model on each cutting element mechanical is pushed based on mechanical model,cutting forces on each cutting element are summed up at the tool rake face coordinates,and then through the coordinate transformation,the instantaneous cutting force model are obtained of the fixed coordinate system.Secondly,the cuting force coefficient is worked out through regression analysis by using Matlab on experimental data according to orthogonal cutting experiments,the instantaneous cutting force is worked out by means of willing the cutiing force coefficient to cutting force model.Then,the models of flying cutter rake face and flying cutter machining motion vector are established.The trajectory interpolation curve of flying cutter tooth is calculated.Flying cutter tooth swept volume is generated from the knife tooth rake face geometry model and the cutter tooth trajectory curve.undeformed chip and instantaneous cogging are formed throgh Boolean operation.Cutting force is solved using the Deform-3D finite element software.Finallya full factorial fly cutting experiment is established,the data of cutting force is collected,the feasibility and effectiveness of mechanical model and finite element model are proved by comparing the experimental results with the mechanical model for predicting results and simulation results.