微细铣削加工过程中微毛刺形成机理的模拟与实验分析(英文)  

Modelling and Experimental Analysis of the Mechanism of Micro-Burr Formation in Micro-End-Milling Process

作　　者：杨凯[1] 白清顺[1] 于福利[1] 梁迎春[1] 

机构地区：[1]哈尔滨工业大学机电工程学院,哈尔滨150001

出　　处：《纳米技术与精密工程》2010年第1期75-83,共9页Nanotechnology and Precision Engineering

基　　金：国家自然科学基金资助项目(50705023);国家杰出青年科学基金资助项目(50925521)

摘　　要：研究了采用硬质合金微铣刀铣削加工硬铝合金微槽结构时微毛刺的形成机理.建立了三维微细铣削加工硬铝合金A l2024-T6的有限元模型,利用该模型动态模拟微毛刺的形成过程.分析了不同进给量与切削刃钝圆半径比值下微毛刺的形成机理,动态模拟了微槽加工过程中切削参数及切削刃钝圆半径变化对微毛刺影响的变化规律.仿真结果表明,随着每齿进给量、背吃刀量及切削刃钝圆半径的增加,微毛刺的尺寸随之增大;切削刃钝圆半径与最大有效应力是影响微毛刺尺寸的主要因素.微细铣削加工过程中,毛刺顶端所受最大有效应变明显比常规铣削加工过程中的最大有效应变高,呈现出显著的尺寸效应.通过微细铣削加工微槽实验,获得了切削参数及切削刃钝圆半径变化对微毛刺形成的影响变化规律,验证了相应有限元模型的正确性.通过数值模拟与实验方法获得了切削刃钝圆半径与毛刺尺寸(毛刺高度和毛刺厚度)的关系曲线,实验与仿真结果最大误差不超过9.8%.进一步验证了所建立的三维有限元模型适于研究并预测毛刺形成机理及毛刺尺寸的变化规律.The micro-burr formation mechanism in the micro-end-milling of microstructure grooves made of A12024-T6 aluminium alloy using tungsten-carbide tool was investigated in this paper. The three-dimensional finite element model of the micro-end-milling of microstructure grooves was developed to dynamically simulate the micro-burr formation process. The mechanism of micro-burr formation was analyzed with variant ratios of feed to tool edge radius and the effect of cutting parameters and various tool edge radii on the micro-burr formation dynamically simulated. Simulation results show that the dimensions of micro-burrs increase with the rise of feed per tooth, cutting depth and tool edge radius, and the tool edge radius and the maximum effective strain are the main factors affecting the dimensions of burrs. The maximum effective strain in micro-end-milling process is much higher than that in the conventional milling process, showing the distinct size effect. Effect of cutting parameters and tool edge radius on the microburr formation was obtained through micro-end-milling experiment of microstructure grooves, which verifies the finite element model. The curves showing the relationship between the tool edge radius and the dimensions of top-burrs （burr height and burr thickness） were obtained in numerical simulation and experiment respectively, with the maximum error within 9.8%. The experimental results also show that the model is suitable for studying the mechanism of micro-burr formation and predicting the dimensions of micro-burrs.

关 键 词：微细铣削 微毛刺 有限元模型 机理 尺寸效应 

分 类 号：TG54[金属学及工艺—金属切削加工及机床]