Study On The Lubrication Flow And Cutting Performance Of Textured Tool

With the continuous development of economy and the increased social environmental awareness,the requirements for product quality and machining methods are increasing.As an effective way to reduce friction in the micro friction gap,micro texture is applied to the rake face of the cutting tools to reduce friction and drag between the tool and chip,so that it can improve the cutting performance of the tool.At present,in the process of cutting lubrication simulation of textured tools,it is difficult to establish an accurate simulation model because of the complexity of micro clearance lubricant flow and cutting process.In this paper,through the establishment of the micro gap textured boundary lubrication and cutting model,the experimental and simulation research of the lubrication process is carried out.The texture parameters are optimized,which provides data and model support for the simulation of the textured tool cutting lubrication process.Firstly,the flow field model of textured boundary lubrication is established.According to the texture of the surface of the cutting tool,the thickness change of the lubricating film,the chip movement speed and textured shape are considered.Meanwhile,the boundary slip effect of the microfluid is added to model the textured boundary lubrication flow field.Secondly,a method to solve the flow field of micro gap textured boundary lubrication is explored.The Reynolds Stokes Galerkin finite element method(R-SGFEM)is proposed.Considering the boundary slip effect of microfluidics,the Reynolds equation is derived by adding Navier slip boundary conditions.Then,the boundary slip velocity is obtained.After that,the Stokes equation is solved by Galerkin finite element method.The velocity and pressure of the flow field are obtained.Finally,the friction coefficient is obtained.Then,the experimental platform of friction lubrication is designed and assembled.The simulation method of textured boundary lubrication flow field is verified and studied.The surface morphology of the upper friction sample is observed after ultrasonic cleaning.As the upper friction sample,the friction coefficient is measured by friction experiment.Comparing with the calculation results of the same simulation model,the results show that the proposed simulation method is suitable for the calculation of texture boundary lubrication process.Next,the coupling effects of texture parameters and slip length on lubrication flow field are studied.The flow field is simulated by changing the geometry size of the model,the moving speed of the chip and the length of the boundary slip.The boundary slip speed,the velocity and pressure of the flow field are observed to explore the influence of the independent variables on the flow field and the lubrication effect.It is found that the depth of texture and the thickness of oil film have opposite regulation on the pressure of the field.They can coordinate and control the change of the sliding velocity of the inner boundary of texture,which provides an effective reference for regulating the boundary shear stress and friction.Finally,the influence of textured tool on cutting lubrication is studied.The internal relations among texture parameters,slip length and cutting force are explained.A textured tool cutting lubrication model is established,and the friction coefficient of the lubrication process is solved by R-SGFEM.Then,the friction coefficient is input into the cutting simulation software of AdvantEdge to solve the cutting process.Then,the simulation results are compared with the cutting experiments of the same model for verification.In the verification process,the friction experiment platform is improved.The pressure sensor of micro fluid is screwed into the friction sample to measure the change of oil film pressure during the friction process and correct the simulation results.The cutting force,cutting stress and chip curl diameter of Ti-6A1-4V workpiece are studied by changing the parameters of tool rake angle,texture size,slip length and cutting speed.The results show that the cutting force can be effectively reduced by using a larger rake angle and adding texture.A smaller tool rake angle and a shorter distance between texture and cutting edge are more likely to produce a secondary cutting of chip by texture.