CN115544687A - Method for predicting cutting performance of precise complex cutter - Google Patents

Method for predicting cutting performance of precise complex cutter Download PDF

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CN115544687A
CN115544687A CN202211228312.9A CN202211228312A CN115544687A CN 115544687 A CN115544687 A CN 115544687A CN 202211228312 A CN202211228312 A CN 202211228312A CN 115544687 A CN115544687 A CN 115544687A
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倪敬
苏忠跃
童康成
蒙臻
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Hangzhou Dianzi University
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Abstract

The invention discloses a method for predicting the cutting performance of a precise complex cutter. The method comprises the following steps: 1. and constructing a thermal coupling cutting simulation model containing the measured cutter and the workpiece in finite element simulation software, and carrying out meshing, assembly positioning and parameter setting. 2. And constructing a modified constitutive model and a cutting scrap friction model. 3. The thermal coupling cutting simulation model is solved by utilizing the updated material rheological stress and yield strength to obtain a cutting simulation result; the cutting simulation results include temperature, contact zone stress, chip distribution and chip morphology. 4. And judging the performance of the measured precise complex cutter according to the cutting simulation result. The invention constructs the corrected constitutive model and the cutter scrap friction model, improves the accuracy of the simulation result of the thermal coupling cutting simulation model, and thus can predict and simulate the cutting performance of the precise complex cutter in a simulation mode.

Description

Cutting performance prediction method for precise complex cutter
Technical Field
The invention relates to the field of cutter cutting performance prediction methods, in particular to a method for predicting the cutting performance of a precise complex cutter.
Background
The cutting machining of the precision complex cutters such as fir-type broach, dovetail-type milling cutter and the like is widely applied to the industries such as aerospace, energy, die, automobile and the like because of the characteristics of high production efficiency, wide machining range, high machining precision and the like, and is often used for machining difficult-to-machine materials such as super alloy and the like. However, the precision complex cutter is difficult to manufacture, high in cost and high in precision requirement, and the problems of high cutting load, high temperature of a cutter-tool-chip contact area and the like exist in the cutting process, and the factors are easy to influence the quality of a processed surface. Therefore, the cutting process needs to be researched to regulate and control the cutting quality of the precise and complex cutter. However, the conventional experimental means is only used for researching the precise and complex cutter, and the method has the defects of high difficulty, high cost and low efficiency, and is difficult to capture the change of each parameter in the dynamic cutting process. The finite element simulation in the cutting process can effectively make up the defects of the traditional means, and the high-performance prediction of the cutting tool is completed through simulation software.
The high-performance modeling of the precise complex cutter mainly comprises models of the cutter, a material constitutive model, cutter scrap friction and the like. The model can be used for effectively simulating and predicting the conditions of temperature, stress, tool abrasion, tool chip bonding and the like of the precise and complex tool in the cutting process, so that the cutting performance prediction of the precise and complex tool is optimized according to the related data. Although the cutting performance prediction simulation of the cutter has many advantages, the prediction precision of the cutter needs to be further optimized, so that the research and development and production of precise complex cutters are accelerated, and the development of aerospace, energy, molds, automobiles and national defense and military industry in China is accelerated. The aims are to carry out more intensive research on the aspects of a cutter model, a material constitutive model, a cutter scrap friction model, a material dynamic rheological property, a time-varying thermal coupling bonding slippage model and the like of a precise complex cutter. At present, when many scholars perform cutting simulation such as broaching, the types of the applied tool models are not complete, and the model precision is not high, so that the conditions of temperature, stress, tool abrasion, tool chip bonding and the like of the tool in the cutting process cannot be accurately shown, and the cutting performance prediction of a precise and complex tool cannot be completed.
Disclosure of Invention
The invention provides a method for predicting the cutting performance of a precise complex cutter, aiming at the problems that the cutting simulation precision is low under the current small cutting depth, the real machining process is difficult to reflect and the like. The invention relates to a simulation method of a cascade correction material constitutive model and a tool bit friction model; the method is a method for modifying the dynamic rheological property of the surface layer material based on the dislocation density theory; the simulation method is a simulation method for continuously developing the friction model correction of the tool bits based on the corrected constitutive model; the simulation method is a simulation method for providing a new friction model of the time-varying thermal-mechanical coupling bonding slippage between the tool scraps based on the SCG equation.
A method for predicting the cutting performance of a precise complex cutter adopts a thermal coupling cutting simulation model containing a modified constitutive model and a cutter scrap friction model to test the cutting performance of the cutting cutter, and comprises the following steps:
step one, constructing a thermal coupling cutting simulation model containing a measured precise complex cutter and a workpiece in finite element simulation software, and carrying out meshing, assembly positioning and parameter setting.
Step two, constructing a constitutive model and a tool scrap friction model, simulating the cutting process of the measured tool to the workpiece by using a thermal coupling cutting simulation model, and obtaining an updated material rheological stress sigma by using the constitutive model ref The updated yield strength σ is obtained using a chip friction model.
Continuously updating the material flow deformation stress sigma of the tested precise complex cutter ref And yield strength σ.
2-1, constructing a constitutive model, wherein the expression of the constitutive model is as follows:
Figure BDA0003880396360000021
wherein the material flow strain σ ref ；σ JC The material is subjected to uniaxial tension, hot bonding, elastoplasticity and rheological stress; alpha (alpha) ("alpha") C Is a constant coefficient of plastic material; g is the shear modulus of the workpiece; b is the size of the Burgers vector; etaIs a strain gradient; μ is the coefficient of friction.
Uniaxial tension hot-bonding elastoplastic rheological stress sigma of material JC The expression of (c) is as follows:
Figure BDA0003880396360000022
wherein ρ SSD To count the dislocation density.
2-2, constructing a tool bit friction model, wherein the expression of the tool bit friction model is as follows:
Figure BDA0003880396360000023
wherein the yield strength σ; τ is the frictional stress; tau is s Critical shear yield strength; sigma n Is normal stress; sigma 0 Is the yield strength at the reference state; beta and n are two work hardening parameters; epsilon is the strain rate; epsilon i Is the initial equivalent plastic strain; sigma' P Is the derivative of the yield strength at the reference pressure; p is the pressure applied to the cutter to be measured; g' T Is the derivative of the shear modulus at the reference temperature; g 0 Is the shear modulus at the reference state; t is the temperature.
Step three, utilizing the updated material rheological stress sigma by the thermal coupling cutting simulation model ref Resolving the yield strength sigma to obtain a cutting simulation result; the cutting simulation results include temperature, contact zone stress, chip distribution and chip morphology.
And step four, judging the performance of the measured precise complex cutter according to the cutting simulation result.
Preferably, the parameters set in the first step include material properties, analysis step and output variables, contact constraints between the precision complex tool and the workpiece, motion characteristics of the precision complex tool, and loads.
Preferably, in the process of grid division, the grid density of the contact area between the precise complex tool and the workpiece and the area with the preset width on the periphery of the contact area is greater than that of other areas.
Preferably, in the third step, if the simulation result is not converged and the convergence result is greater than the difference threshold, the first step is re-entered to perform meshing, assembly positioning and parameter setting.
The invention has the beneficial effects that:
1. the method constructs the corrected constitutive model and the tool scrap friction model, improves the accuracy of the simulation result of the thermal coupling cutting simulation model, and can predict and simulate the cutting performance of the precise complex tool in a simulation mode.
2. The invention realizes and establishes a cascade correction material constitutive model and the tool bits, corrects the surface layer material dynamic rheological property based on the dislocation density theory and corrects the new friction model method of the time-varying thermal coupling bonding slippage between the tool bits based on the finite element simulation software, realizes the cutting performance prediction of the precise and complex tool, and further realizes the precise simulation test of the precise and complex tool.
3. The method uses finite element simulation software, takes the workpiece cut by the precise complex cutter as a basis, carries out simulation on the precise complex cutter, has accurate simulation result and high reliability, can obtain data which is difficult to obtain in an experiment, can predict the whole machining process, and has high guiding value for practice.
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FIG. 1 is a schematic diagram of a simulation model of the present invention for a precise complex tool and workpiece;
FIG. 2 is a flow chart of the present invention.
Reference numerals: in FIG. 1, 1-precision complex tool model; 2-workpiece model.
Detailed Description
Other advantages and capabilities of the present invention will be apparent to those skilled in the art from the present disclosure by describing the embodiments of the present invention with specific examples. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It should be noted that the features in the following embodiments and examples may be combined with each other without conflict.
As shown in fig. 2, a method for predicting the cutting performance of a precise complex cutter uses a thermal coupling cutting simulation model containing a modified constitutive model and a cutting debris friction model to perform a cutting performance test of the precise complex cutter, and comprises the following steps:
step S1, pre-processing a precise complex cutter:
aiming at the precise complex cutter, a thermal coupling cutting simulation model is constructed, material attributes, grid division, assembly positioning, creation of analysis steps and output variables, setting of contact constraint between the precise complex cutter and a workpiece, setting of motion characteristics and load application of the precise complex cutter are defined.
S2, correcting the constitutive model and the tool scrap friction model: correcting the dynamic rheological property of the surface layer material based on the dislocation density theory, correcting a material constitutive model, and establishing a corrected tool bit friction model based on an SCG (scale-invariant feature graph) equation; the tool scrap friction model fully considers the characteristic of time-varying thermal coupling bonding between tool scraps to establish a cascade correction material constitutive model and a tool scrap model, and corrects the dynamic rheological property of a surface layer material based on a dislocation density theory and a new friction model of time-varying thermal coupling bonding slippage between tool scraps.
S2.1, correcting the constitutive model: and (3) introducing a strain gradient theory based on a Taylor dislocation mechanism to describe the cutting process scale effect, so that the corrected material constitutive relation is a function containing a strain gradient term and is expressed as follows:
σ＝f(σ JC eta formula (1)
Where η is a strain gradient term that incorporates higher order strain gradients and dislocation densities to govern the behavior of the material at the microscale; sigma JC The material uniaxial tension hot-sticking elastoplasticity rheological stress obtained for the traditional hot-sticking elastoplasticity J-C constitutive equation; σ is the total rheological stress after considering the dimensional effect.
The traditional Johnson-Cook model can be used for describing the relationship between the rheological stress and the strain of a metal material under large strain rate due to simple form, and can be widely used for describing the constitutive relationship of the material in the cutting process, wherein a strain hardening term, a strain rate strengthening term and a temperature softening term are expressed in the form of products, and are specifically expressed as follows:
Figure BDA0003880396360000041
wherein ε is strain;
Figure BDA0003880396360000042
is the strain rate;
Figure BDA0003880396360000043
is a reference strain rate; t is 0 Is a reference temperature; t is melt Is the material melting temperature; a, B, C, n and m are constants, and the numerical values of the constitutive parameters of J-C are shown in Table 3.
The Taylor dislocation density theory shows that the plastic hardening of the material is realized by co-casting the statistical storage dislocation associated with the plastic strain and the geometrical essential dislocation influencing the plastic strain gradient, and the shear stress of the material is increased, and the specific expression is as follows:
Figure BDA0003880396360000044
in the formula, alpha C Is a constant coefficient of plastic material; g is shear modulus; b is the size of the Burgers vector; rho total Is the total dislocation density, ρ SSD For statistical dislocation density, p GND The dislocation density is geometrically necessary.
To achieve a more accurate expression of the rheological stress sigma ref Introducing coefficients k and μ, taking k to be 3 for anisotropic materials with a γ strengthening term like Inconel 718, equation (3) becomes:
Figure BDA0003880396360000051
wherein σ ref For material rheological stress, σ JC The material is the uniaxial tension thermal bonding elastoplasticity rheological stress, the value of which is related to the statistical memory dislocation, and the expression is shown in formula (5):
Figure BDA0003880396360000052
for polycrystalline materials, the geometrically necessary dislocation density ρ GND And the strain gradient η satisfy the relation (6):
Figure BDA0003880396360000053
by substituting formula (5) and formula 6 into formula 4, a modified J-C constitutive model based on MSG strain gradient theory can be obtained, and the expression is as follows:
Figure BDA0003880396360000054
s2.2, correcting the friction model of the tool bits: according to formula (8) and formula (9)
Figure BDA0003880396360000055
Figure BDA0003880396360000056
Wherein, τ and τ s Is a shear stress; mu is a friction coefficient; sigma n Is normal stress; sigma is yield strength; sigma 0 Is the yield strength at the reference state; beta and n are work hardening parameters; epsilon is the strain rate; epsilon i Is the initial equivalent plastic strain; sigma' P Is the derivative of the yield strength at the reference pressure; g' T Is the derivative of the shear modulus at the reference temperature; g 0 Is the shear modulus at the reference state; t is the temperature.
As during shearing, a large amount of time-varying heat and pressure is generated, which affects the shear stress and thus the yield stress and thus the friction. The method updates the bonding slippage effect and friction seen by the tool bits in real time by continuously acquiring various parameters in the simulation process.
And S3, submitting the thermal coupling cutting simulation model to a finite element simulation software solver for operation to obtain an operation result. In the thermal coupling cutting simulation model, the material flow deformation stress sigma obtained according to the step S2 ref Inputting the yield strength sigma into a thermal coupling cutting simulation model to replace the flow stress parameter and the yield strength parameter in the original model; obtaining a cutting simulation result; due to material flow strain sigma ref And the data of the yield strength sigma are more accurate, so that the temperature, the contact area stress, the chip distribution and the chip form in the cutting simulation result are more accurate.
The obtained result is compared with the actual result. And if the simulation is not converged or the simulation is greater than the difference threshold, the step S1 is re-entered, and the parameters of the thermal coupling cutting simulation model are adjusted.
In the embodiment, a fine grid is adopted in a contact area of a precise complex cutter and a workpiece, a small range area around the contact area is adopted in the simulation, and a coarse grid is adopted in a region far away from the contact area. In the cutting process, the workpiece model is clamped on the machine tool through the clamp, the bottom surface of the workpiece model can be regarded as completely fixed, and the boundary condition of full constraint is applied to the bottom surface of the workpiece model during finite element simulation.
The method is characterized in that finite element simulation software is used for simulating the precise and complex cutter in the cutting process, and stress-strain, temperature, cutter-tool-chip distribution and cutter chip bonding conditions need to be concerned, so that a cascading correction material constitutive model and cutter chip friction, a surface layer material dynamic rheological property is corrected based on a dislocation density theory and a cutter chip time-varying thermal coupling bonding slippage new friction model are realized and established by means of simulation software for predicting the cutting performance of the precise and complex cutter, and the method for predicting the cutting performance of the precise and complex cutter is further realized.
In step S1, as shown in FIG. 1, establishing a simulation model of the cutting process of the precise complex cutter; the simulation model comprises a precise complex cutter model 1 and a workpiece model 2, relevant sizes of cutters are modeled according to the precise complex cutters produced actually, and then the models are led into finite element simulation software. The length of this embodiment is in mm, and the same dimensions are used in the following. After the three-dimensional models of the precise complex cutter and the workpiece are completely established, the material properties of the three-dimensional models of the precise complex cutter and the workpiece need to be defined in a material characteristic function module of finite element simulation software respectively, so that the simulation analysis of the physical quantity can be carried out.
In consideration of the performance of a precise and complex cutter, the cutter is made of T15 powder metallurgy high-speed steel, and GH 4169 steel is selected as a workpiece material. The material parameters of the tool model and the workpiece model in this example are shown in tables 1 and 2:
TABLE 1 precise Complex tool Material parameters
Figure BDA0003880396360000061
TABLE 2 workpiece Material parameters
Figure BDA0003880396360000062
The model is described by adopting the stress-strain relation of a J-C material constitutive model GH 4169 steel, wherein the J-C damage model is as follows:
Figure BDA0003880396360000071
wherein, the first and the second end of the pipe are connected with each other,
Figure BDA0003880396360000072
the non-dimensional plastic strain rate of the alloy,
Figure BDA0003880396360000073
is the strain rate of the quasi-static experiment;
T * ＝(T-T r )/(T m -T) a dimensionless temperature, T being the test piece ambient temperature;
Figure BDA0003880396360000074
representing three degrees of stress, where m In order to be a ball stress,
Figure BDA0003880396360000075
is the Mises equivalent stress.
The J-C constitutive parameters and the J-C injury parameters are shown in tables 3-4:
TABLE 3J-C constitutive model parameters for GH 4169 steels
Figure BDA0003880396360000076
TABLE 4J-C Damage model parameters for GH 4169 steels
Figure BDA0003880396360000077
Then, the contact area of the precise complex tool model and the workpiece model adopts a fine grid, and the remote area adopts a coarse grid, as shown in figure 1. And assembling and positioning the divided precise complex tool model and the workpiece model of the grid. And selecting a display dynamic analysis step according to the cutting motion characteristics, defining the cutting force in the cutting process in historical variables, and defining displacement, speed, acceleration, stress and strain in field variables. And defining the friction and the constraint thereof between the precision complex tool and the workpiece according to the contact characteristics of the precision complex tool and the workpiece. The invention mainly focuses on the stress, strain, temperature, cutting chip distribution and cutting chip bonding condition of the precise complex cutter in the cutting process, and the cutter is arranged to be a rigid body, so that the analysis and calculation time can be shortened, and the accuracy of a calculation result can be improved. According to the contact state between the precision complex tool and the workpiece after the precision complex tool cuts off the workpiece, a modified Coulomb friction law is applied to define the friction characteristic between the precision complex tool and the workpiece, and the friction coefficient f =0.24. Then, boundary conditions of six direction constraints of the bottom surface are applied to the matrix model; controlling the movement of the cutter, and constraining the X-direction displacement as shown in figure 1; in addition, the cutting force in the cutting process is defined in the historical variable, and the output of the historical variable only needs to be directed at the tool reference point; displacement, velocity, acceleration, stress, strain are defined in the field variables, and the output of the field variables is for the entire three-dimensional model.
In step S2, the J-C constitutive parameters used are shown in Table 3.
In step S3, the previously established simulation model is submitted to a solver of finite element simulation software for solving operation, after the operation is completed, cutting force, stress-strain, material damage, tool chip distribution and tool chip adhesion are checked in a post-processing module of the finite element simulation software, the operation result is analyzed and evaluated in combination with an experiment and actual cutting, if the simulation result is greatly different from the actual result or the result is not converged in the operation process or the simulation result is close to the actual result, the operation returns to step S1, the simulation model is changed, and the most appropriate cutting process parameter combination is found through a precise grid, cutting force, material damage and the like.
The simulation method is different from the roughness and inaccuracy of the conventional simulation, and only needs finite element simulation software to realize cascade correction of a material constitutive model and the friction of the tool bits, correction of the dynamic rheological property of the surface layer material based on the dislocation density theory and the time-varying thermal coupling between the tool bits, bonding and sliding of a new friction model, thereby realizing the prediction of the cutting performance of the precise and complex tool.
As noted above, while the present invention has been shown and described with reference to certain preferred embodiments, it is not to be construed as limited to the invention itself. Various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (4)

1. A method for predicting the cutting performance of a precise complex cutter is characterized by comprising the following steps: the method comprises the following steps:
step one, constructing a thermal coupling cutting simulation model containing a measured cutter and a workpiece in finite element simulation software, and carrying out meshing, assembly positioning and parameter setting;
step two, constructing a constitutive model and a tool scrap friction model, simulating the cutting process of the measured tool to the workpiece by using a thermal coupling cutting simulation model, and obtaining an updated material rheological stress sigma by using the constitutive model ref Obtaining an updated yield strength sigma by using a tool bit friction model;
continuously updating the material flow strain sigma of the tool to be measured ref And yield strength σ;
2-1, constructing a constitutive model, wherein the expression of the constitutive model is as follows:
Figure FDA0003880396350000011
wherein the material flow strain σ ref ；σ JC The material is subjected to uniaxial tension, hot bonding, elastoplasticity and rheological stress; alpha is alpha C Is a constant coefficient of plastic material; g is the shear modulus of the workpiece; b is the size of the Burgers vector; eta is the strain gradient; mu is a friction coefficient;
uniaxial tension hot-bonding elastoplastic rheological stress sigma of material JC The expression of (a) is as follows:
Figure FDA0003880396350000012
wherein ρ SSD Statistical dislocation density;
2-2, constructing a tool bit friction model, wherein the expression of the tool bit friction model is as follows:
Figure FDA0003880396350000013
wherein the yield strength σ; τ is the frictional stress; tau. s Critical shear yield strength; sigma n Is normal stress; sigma 0 Is the yield strength at the reference state; beta and n are two work hardening parameters; epsilon is the strain rate; epsilon i Is the initial equivalent plastic strain; sigma' P For yield strength at reference pressureA derivative; p is the pressure applied to the cutter to be measured; g' T Is the derivative of the shear modulus at the reference temperature; g 0 Is the shear modulus at the reference state; t is the temperature;
step three, utilizing the updated material rheological stress sigma by the thermal coupling cutting simulation model ref Resolving the yield strength sigma to obtain a cutting simulation result; the cutting simulation result comprises temperature, contact zone stress, chip distribution and chip form;
and step four, judging the performance of the measured cutter according to the cutting simulation result.
2. The method for predicting the cutting performance of the precise complex cutter according to claim 1, wherein: the parameters set in the first step comprise material properties, analysis steps and output variables, contact constraint between the precise and complex cutter and the workpiece, and motion characteristics and loads of the precise and complex cutter.
3. The method for predicting the cutting performance of the precise complex cutter according to claim 1, wherein: in the process of grid division, the grid density of a contact area of the precise complex cutter and the workpiece and a peripheral area with preset width is greater than that of other areas.
4. The method for predicting the cutting performance of the precise complex cutter according to claim 1, wherein: and in the third step, if the simulation result is not converged and the converged result is greater than the difference threshold, the first step is re-entered, and grid division, assembly positioning and parameter setting are carried out.
CN202211228312.9A 2022-10-09 2022-10-09 Method for predicting cutting performance of precise complex cutter Pending CN115544687A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115952696B (en) * 2023-03-13 2023-05-23 武汉益模科技股份有限公司 Tool full life cycle management method based on simulation prediction and cost model

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115952696B (en) * 2023-03-13 2023-05-23 武汉益模科技股份有限公司 Tool full life cycle management method based on simulation prediction and cost model

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