The Simulation And Optimization On The Microtextured Ceramic Cutting Tools Of Al₂O₃-T_iC With In-situ Forming

Micro texture of tool surface with micro topography has been proved to optimize cutting performance of cutting tools,and related research works have made some progress.Due to the limitation of manufacturing and manufacturing capability,the manufacture of high-precision micro texture knives is more difficult,which afffects the research of cutting performance of micro texture tools.In this paper,the cutting performance of the micro textured ceramic tool is simulated and analyzed by the finite element method.On the basis of the cutting test,the simulation parameters are adjusted,and the factors affecting the cutting performance of the micro texture in the metal cutting process are explored.The main work is as follows:(1)The present situation of the micro texture cutting simulation and the existing problems in the simulation process are summarized,and the advantages of the common cutting simulation softweare and the parameter meaning and setting basis which need to be set in the simulation are analyzed,and the results of the result cloud and data chart are displayed by using the post processing function of the cutting simulation software.(2)The 3D model of non woven Al2O3-TiC ceramic tool and transverse groove micro texture Al2O3-TiC ceramic tool was established according to the literature,and the model was introduced into the finite element simulation software for cutting simulation of cutting 45#steel.The results show that the main cutting force of the Al2O3-TiC ceramic tool with transverse groove micro texture is smaller,the cutting temperature of the cutting tool is low,and the changing trend of the main cutting force and the cutting temperature at different cutting speeds has some difference.(3)The cutting tool was made by the 3D model of the transverse groove micro texture Al2O3-TiC ceramic tool.The related tools were prepared by the preparation method of the micro texture tool in situ and the cutting test was carried out.The experimental results show that compared with the simulation results,the trend of the main cutting force and the cutting temperature is different under the change of speed,and the simulation and the test can be better in accordance with the cutting speed greater than 150m/min.(4)A large number of cutting simulations are carried out on the concave pit and the convex shape microtexture Al2O3-TiC Ceramic Cutters using the adjusted simulation parameters.These simulations are carried out mainly around the width,depth,distance and distance dimension of the micro texture,and the other parameters remain unchanged when a certain size is changed.In this way,the relationship between tool cutting performance,main cutting force,cutting temperature and cutting stress and micro texture size is obtained.The simulation results show that in the cutting 45#steel,the Al2O3-TiC convex micro texture ceramic tool reduces the main cutting force by 43.8%,and the Al2O3-TiC concave micro texture ceramic tool reduces the main cutting force by 31.3%,and the concave micro texture can reduce the cutting temperature range.Up to 18.1%,convex micro texture can reduce the cutting temperature range to 27.4%.(5)Optimization and analysis of data obtained from simulation and data fitting are made,and approximate correlation function and regular function curve are obtained.On this basis,we get the extreme value of the function,that is,the more optimized micro texture size,and do the cutting simulation and experiment again.The research shows that the cutting temperature of the micro texture Al2O3-TiC ceramic tool is also the best when the main cutting force is optimized.It is only necessary to optimize the main cutting force.(6)Select the transverse groove micro texture Al2O3-TiC ceramic tool after optimizing the results of the design of the graphite punch and make the Al2O3-TiC ceramic cutting tool,using this tool to carry out the cutting test.The results show that the optimized micro texture cutting tool can reduce the main cutting force of 19%.The cutting temperature reduce 14.6%.The protruding micro texture can play a more important role in reducing friction and cooling than pits micro texture.This is mainly due to the particularity of its structure.The simulation results show that the smaller the size of the convex micro texture is,the more close the cutting edge is,the better the effect on the cutting performance of the cutter.Above all,we can see that micro texture has potential to be ignored in tool cutting.