Simulation Analysis And Process Optimization Of Tool Wear And Workpiece Deformation For Machining Shaft Parts

As a key part of the mechanical structures,shaft parts play a very important role in automotive engines and aero engines,such as crankshafts and aero-engine shafts.There are many machining processes of shaft parts,including turning,milling,boring,drilling etc.Tool life directly affects the production cost in crankshaft processing.Therefore,how to reduce tool wear rate and improve tool life is always the focus of enterprises.In the aero engine,machining deformation of various thin-walled parts is very obvious because of the poor rigidity such as aero-engine shaft.And it is of great significance to control the machining deformation of the aeronautical thin-walled parts.Therefore,taking the typical shaft parts of crankshaft and aero-engine shaft as the research objects,the tool wear and machining deformation are studied in this paper.For automotive engine shaft part,the tests of crankshaft material FCD600 are carried out and the differences in hardness,graphite morphology,metallographic structure and element composition between two crankshaft manufacturers Liuji and Yinfeng are compared.The cutting performance is also compared after turning experiments.And the results provid a suggestion for the manufacturers to improve the cutting performance of crankshaft blank.The three periods of tool wear in turning FCD600 with cemented carbide cutting tool are studied.In addition,the relationship between the tool flank wear and the workpiece surface roughness is analyzed.Furthermore,the orthogonal test of four factors and four levels is conducted to establish an empirical model of tool flank wear in cutting FCD600 with cemented carbide cutting tool,and the influences of cutting time,speed,width and feed on tool flank wear are analyzed.Based on the simulation software Advantedge,a 2D simulation model is established and the effects of tool wear on cutting force and temperature are analyzed.According to the concepts of serrated degree and frequency,the serrated chips in the experiment and simulation are compared and the results show a good agreement.In the process of turning the crankshaft thrust face,the process optimization is carried out from two aspects of cutting tool selection and cutting parameters,and experimental verification and production application are successfully conducted.For aero engines shaft part,simulation models of milling and drilling AISI-4150 are established based on Advantedge.The cutting forces generated in milling and drilling are compared,and the workpiece deformation caused by the drilling force is studied based on ANSYS when the circumferential holes of the aero-engine shaft are machined in the linear-reciprocating path.In the process of drilling the circumferential holes,in order to control the maximum deformation,the spiral machining path is put forward.The simulation results show that the machining deformation in the spiral machining path is effectively reduced.