The Research On Wear Model And Prediction Of Micro-arc Diamond Tool In Copper Cutting

Ultra-precision machining is can achieve the highest accuracy grade of machining method,the machining accuracy can be Dana meter level,its application is becoming more and more widely in the field of optical,with special shape of the surface of the microstructure in the optical field of ultra-precision measurement is more widely used,particular microstructure and micro components you need to have a good edge of the circular arc diamond cutting tool processing to obtain.In order to ensure the accuracy of ultra-precision machining,the machining process of the micro arc diamond tool wear needs to be addressed,tool wear will directly affect the amount of finished material surface precision and surface integrity,affect the dimensional accuracy and shape accuracy,so the micro arc diamond tool wear mechanism,the wear morphology and wear volume forecast is important.Firstly,based on the Deform-3D finite element software,the process of micro-arc diamond tool cutting pure copper is primarily analyzed,and the cutting geometric model,material constitutive model and friction model which accord with the actual situation are established in this dissertation.In this experiment,the influence of cutting parameters on cutting force,cutting temperature and the maximum equivalent stress of the tool are obtained by changing the cutting tool’s rake-flank angle,arc radius,blunt radius and cutting parameters,and the transfer rules of cutting heat are obtained,as well as the temperature field and stress field under various conditions.Secondly,by selecting the suitable micro-arc cutting tool processing technology,the combination of the rake and flank face crystal planes,rake-flank angle combination,and material of the micro-arc cutting tool are changed.Obtain a cylindrical flank tool with an arc radius of 50μm,a complete cutting edge,which meet the production requirements.In this research,by selecting the appropriate micro-arc cutter processing technology,changing the crystal surface combination,rake-flank angle combination and material of the front and rear knife surfaces of the micro-arc cutter to obtain the cylindrical rear knife surface with a circular arc radius of 50 μm,complete cutting edge without defects and circular waviness that fully satisfies the production requirements.In addition,the Advant Edge finite element software is applied into the tool wear simulation,and the pure copper material J-C constitutive model fitting data is for the establishment of pure copper material Power-Law constitutive model.Based on the USUI wear model,the bond wear model for micro circular cutting of pure copper materials is established.The corresponding undetermined parameters required for the calculation of the wear rate are obtained through simulation for the prediction of wear morphology and wear amount in the front and rear blades and cutting edges.Based on the wear morphology of the front and rear blades and the geometric characteristics of the micro-circular cutter,the crater and blade wear volume of the rake surface are modeled to quantitatively evaluate the amount of wear.Lastly,the tool stress,temperature field distribution and chip moving speed obtained by finite element simulation are used to obtain the rake face wear rate prediction curve.Compared with the wear simulation profile,the influence of the cutter geometry parameters and machining process parameters on the maximum wear depth of the cutter,the length of the wear belt,the maximum wear depth and the edge distance are obtained.Then,the cutting simulation models with different values in KT,KF,KB and VB tools are established to obtain the results about how does tool wear affect cutting forces and cutting heat.