刀具磨损和变摩擦系数对切削力的影响  

Effect of tool wear and variable friction coefficient on cutting force

作　　者：郐吉才[1,2] 段云乾 李新 刘石安[1] ARDASHEV Dmitrii Valerievich[3] KUAI Jicai;DUAN Yunqian;LI Xin;LIU Shian;ARDASHEV Dmitrii Valerievich(Henan Polytechnic University,School of Mechanical and Power Engineering,Jiaozuo 454003,China;Henan International Joint Laboratory of Advanced Electronic Packaging Materials Precision Forming,Jiaozuo 454003,China;South Ural State University,Department of Automation Engineering,Chelyabinsk 454080,Russia)

机构地区：[1]河南理工大学机械与动力工程学院,河南焦作454003 [2]河南省先进电子封装材料精密成形国际联合实验室,河南焦作454003 [3]南乌拉尔国立大学,俄罗斯车里雅宾斯克454080

出　　处：《光学精密工程》2024年第14期2211-2224,共14页Optics and Precision Engineering

基　　金：国家自然科学基金项目(No.51475147);河南省攻关项目(No.222102520003);俄罗斯联邦科学与高教部项目(No.FENU-2020-0020)。

摘　　要：刀具磨损和摩擦系数对切削力、表面质量有显著影响。为进一步研究刀具磨损和摩擦系数对切削力的影响规律,提出了同时考虑刀具磨损和变摩擦系数的切削力模型。首先分析了刀具磨损对刃口半径的影响规律,指出随刀具磨损增加,刃口半径增加;其次明确了刀具磨损及刃口半径对最小切削厚度的影响规律,认为最小切削厚度随刀具磨损、刃口半径的增加而增加。进一步用单晶金刚石刀具切削铝合金,并在切削深度、进给速度、刀具刃口半径、刀具磨损宽度以及恒定摩擦系数与变摩擦系数等方面进行了对比。研究表明,随切削深度、进给速度增加,法向切削力与切向切削力增加;随刃口半径从150 nm增加到450 nm,切向力增加了1.13倍,法向力增加了2.12倍;随刀具磨损宽度从0增加到0.55μm,切向力增加了1倍,法向力增加了约7倍;恒定摩擦系数切削力最大误差高达41%,变摩擦系数切削力最大误差在11%以内。因此,同时考虑了刀具磨损与变摩擦系数的切削模型与实际切削过程更加吻合。Tool wear and friction coefficients have a big impact on the cutting force and surface quality.To study the effect of tool wear and friction coefficients on cutting force,an cutting force model was devel⁃oped,taking into account tool wear and variable friction coefficients.First,the edge radius for worn tool was looked at.It was shown that the edge radius gets bigger as the tool wears down.Next,the minimum cutting thickness for worn tool was explained.It was thought that the minimum cutting thickness gets bigger as tool wear and edge radius get bigger.Lastly,the cutting of Al alloy was researched by single crystal diamond tool,and compared the variations in cutting force with respect to cutting depth,feed speed,tool edge radius,tool wear width,and constant and variable friction coefficients.It was shown that the normal and tangential cutting forces increase with increasing depth of cut and feed rate.When the edge radius went from 150 nm to 450 nm,the tangential force went up by 1.13 times and the normal force went up by 2.12 times.When the tool wear width went from 0 to 0.55μm,the tangential force went up by 1 time and the normal force went up by about 7 times,and the constant friction coefficient model has a maximum error in cutting force of 41%,whereas the variable friction coefficient model has a maximum error within 11%.Hence,the cutting model,which accounts for both tool wear and changing friction coefficients,aligns more closely with the real cutting process.

关 键 词：切削力模型 刀具磨损 变摩擦系数 金刚石刀具 

分 类 号：TG580[金属学及工艺—金属切削加工及机床]