| High silicon aluminum alloy is mainly composed of two elements of silicon and aluminum,and its silicon content is 25%-70%(mass%).It has the characteristics of high specific strength,high specific stiffness,small density,good heat dissipation,strong conductivity,corrosion resistance and wear resistance.It has been widely used in the fields of aviation,automobile,electronic sealing and so on.However,the processing of high silicon aluminum alloy is also difficult and easy to produce adhesion,which is easy to wear tool wear.Therefore,the milling cutter with high hardness,wear-resistant diamond coated milling cutter and Ti Al N coating can improve the processing efficiency,machining accuracy and processing quality of high silicon aluminum alloy.The wear characteristics of high silicon aluminum alloy with diamond coated milling cutter and Ti Al N coated milling cutter are studied,which can effectively improve the processing efficiency of high silicon aluminum alloy,optimize the milling parameters of the coated tool and prolong the service life of the coated tool.It is of great value to study the friction and wear of high silicon aluminum alloy,but its research cost is high and the test period is long.If Deform-3D finite element simulation software is used to simulate the processing process of high silicon aluminum alloy,It is proved that it is correct and feasible,and will provide more convenience for future research on friction and wear of high silicon aluminum alloy.In this paper,two kinds of coated milling cutters are used to milling high silicon aluminum alloy(Al-50%Si)for single factor and orthogonal experimental design.The cutting force and the contact surface temperature in the milling process are measured by experiments.The friction coefficient of each group is obtained by the formula,and the influence of milling parameters on friction coefficient and the relationship between milling temperature and friction coefficient are analyzed.Then through the friction coefficient measured by the friction experiment,using the orthogonal design of the friction experiment,the finite element simulation software Deform 3D is used to simulate the milling of high silicon aluminum alloy with the coated milling cutter,and the wear quantity of the simulation orthogonal test is analyzed by the extreme difference method.The following conclusion is obtained: the most influence on the wear of the two kinds of coated milling cutters is obtained.Large milling parameters are spindle speed,and with the increase of spindle speed,the wear volume increases obviously.A group of milling parameters that have the least influence on the wear of the coated milling cutter can be obtained by the extreme difference method,which plays a guiding role in the rational selection of cutting tools and cutting parameters in actual production.At last,the wear test was carried out in the NC machining center.The real wear of the wear test was measured by metallographic microscope,and the wear of the milling cutter was analyzed.The following conclusion was obtained: the wear amount increased with the increase of the spindle speed.The change law is consistent with the change law of the simulation,which shows that the Deform-3D finite element simulation software is feasible to analyze the friction and wear of the high silicon aluminum alloy by the coated milling cutter. |
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