金属切削加工有限元仿真及薄壁件变形预测研究-机械制造及其自动化专业论文.docx

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2018-05-05 发布于上海
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金属切削加工有限元仿真及薄壁件变形预测研究-机械制造及其自动化专业论文.docx

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金属切削加工有限元仿真及薄壁件变形预测研究-机械制造及其自动化专业论文

AbstractMetalcuttingprocessisatypicalthermo-mechanicalprocesswhichgoestogetherwiththeoccurrenceofhighstrain,highstrainrateandinstanttemperatureincreasing.Intheforetime,researchersfindthesevariablesbyusingexperimentaltechniqueswhichmakestheinvestigationverytimeconsumingandexpensive.Atthispoint,withtherapiddevelopmentofcomputertechnology,finiteelementmodellingandsimulationbecomesmaintool.Bycombinationofthefiniteelementmethod(FEM)andcuttingtechnology,simulation of metal cutting can predict important variables such as temperature,cuttingforces，chipplasticformation，stressandstraindistributionsinthecuttingprocess.Theaimofthisthesispaperiscreateanumericalmodeltoconductfurtherresearchonmetalcuttingprocess.Basedonthedomesticandforeigninvestigatedstatusfromthetwodimensional(2D)orthogonalcuttingandthreedimensional(3D)obliquecuttingprinciples,andthekeymodelingtechniquesofthermo-mechanicalcouplingforthesimulation，amethodcombiningtheoreticalanalysiswithfiniteelement calculation and experiment is adopted in this dissertation to study thedistortionandvariablesprediction.ThroughAluminumalloy7050-T7451continuouschipof2DFEMmodelwasestablishedandanalyzedthedistributionlawofstress,strain,cuttingforceandtemperature.WithresearchpurposesofserratedchipformationmechanismoftitaniumalloyTI-6Al-4V,theFEMmodelisanalyzedchipformationtoachieve2Dsimulationofserratedchip.Thecuttingforcesarevalidatedbycomparingsimulationresultswith experimental resultsavailableintheliterature.Accordingtothemillingprocessofaluminumalloy7050-T7451,a3Dthermo-mechanicalcouplingFEMisconstructedtosimulatethemillingprocess.ThechipmorphologyandcuttingforcesofFEMmodel weresimilarwiththatobtainedfromexperiment.Subsequently,3DmillingFEMmodelwithsolidcarbidemillingcutterofaluminumalloywasestablished.Thesimulateresultssuchasresidualstress，thin-walledpartmachiningdeformationswerepresentedandanalyzed.ThethesisresultsshowthattheFEMisaneffectivetoolforsimulatingthecuttingprocess.Theseimportantcuttingvariablescanbepredictedwithoutdoin