CN115544844A - Cutting fluid injection speed optimization method based on high-performance modeling simulation - Google Patents
Cutting fluid injection speed optimization method based on high-performance modeling simulation Download PDFInfo
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Abstract
The invention discloses a cutting fluid injection speed optimization method based on high-performance modeling simulation; the method comprises the following steps: s1, constructing a thermal power and fluid coupling cutting simulation model comprising a cutter, a workpiece and an Euler domain; and S2, submitting to operation analysis under the condition that the cutting fluid jet speed is zero. S3, taking the cutting simulation model obtained in the steps S1 and S2 as a pre-simulation model; copying a pre-simulation model as a secondary simulation model; and restarting the secondary simulation model, and taking the simulation result of the pre-simulation model as the initial state of the secondary simulation model. And S4, setting a plurality of different cutting fluid injection speeds, and submitting the secondary simulation model to operation analysis respectively to obtain simulation results corresponding to the different cutting fluid injection speeds. The invention can observe the conditions of the cutting fluid injection speed to the chip breaking and the temperature by changing the cutting fluid injection speed, thereby realizing the optimization of the cutting fluid injection speed.
Description
Technical Field
The invention belongs to the technical field of metal processing, and particularly relates to a cutting fluid injection speed optimization method based on high-performance modeling simulation.
Background
The metal cutting fluid is widely applied to various cutting operations, such as turning, drilling, grinding, milling, planing, broaching and the like, heat and abrasion can be generated by friction between a cutter and a workpiece in the machining process, the heat can be taken away by the cutting fluid to play a cooling role, chips can be taken away in the cutting process, and the chip breaking function is realized. However, since the cutting fluid injection rate is different and the effect of achieving the heat exchange and chip breaking functions is also different, it is necessary to optimize the cutting fluid injection rate in order to improve the quality of various cutting operations. However, the difficulty of optimizing the cutting fluid injection speed by using the traditional test means is high, the cost is high, the efficiency is low, and the variation of each parameter in the cutting dynamic process is difficult to capture.
Although the current cutting fluid for metal processing has many advantages, the cutting fluid injection speed needs to be further optimized, so that the development of the metal processing field is accelerated. To achieve this goal, further research into the preferred aspect of the cutting fluid injection rate is needed. At present, cutting simulation research on adding cutting fluid is less, and the simulated cutting fluid injection speed is single, so that the influence of different cutting fluid injection speeds on cutting in the cutting simulation process cannot be accurately shown, and the optimization of the cutting fluid injection speed cannot be completed in the prior art.
Disclosure of Invention
The invention aims to provide a cutting fluid injection speed optimization method based on high-performance modeling simulation, aiming at the problems that the cutting fluid injection speed of metal machining is difficult to optimize, the influence of the cutting fluid on the cutting machining is difficult to monitor in real time and the like. The invention is a method for carrying out dry cutting firstly and then adding cutting fluid to carry out cutting simulation; the method is a cutting simulation method for processing large deformation based on coupling Euler Lagrange; is a method of reducing the amount of computation using restart analysis; the method is a method for cutting simulation by using thermodynamic liquid coupling; the method is a method for observing the conditions of chip breaking and temperature of different cutting fluid injection rates by changing the cutting fluid injection rate so as to obtain the optimal cutting fluid injection rate for metal processing.
A cutting fluid injection speed optimization method based on high-performance modeling simulation comprises the following steps:
s1, constructing a thermal power and fluid coupling cutting simulation model containing a cutter, a workpiece and an Euler area, and carrying out grid division, assembly positioning, euler material distribution area and parameter setting.
And S2, submitting the thermal fluid coupling cutting simulation model to operation analysis under the condition that the cutting fluid jet speed is zero, and obtaining a simulation result. If the simulation result is not converged, adjusting the parameters of the thermodynamic liquid coupling cutting simulation model and then submitting the parameters to operational analysis again until the simulation result is converged.
S3, taking the cutting simulation model obtained in the S1 and the S2 as a pre-simulation model; copying a pre-simulation model as a secondary simulation model; and restarting the secondary simulation model, and taking the simulation result of the pre-simulation model as the initial state of the secondary simulation model. Resetting the constraint parameters of the cutting fluid in the secondary simulation model; the constraint parameter of the cutting fluid is that the cutting fluid is sprayed to the contact area of the cutter and the workpiece at a set spraying speed while moving along with the cutter.
And S4, setting a plurality of different cutting fluid jet speeds, submitting the secondary simulation models to operation analysis respectively to obtain simulation results corresponding to the different cutting fluid jet speeds, evaluating the influence of the cutting fluid jet speed on the metal processing performance according to the difference of the simulation results, and selecting the cutting fluid jet speed used in the processing.
Preferably, in step S1, the parameters of the thermal coupling cutting simulation model include the range of euler domains, material properties, meshing, assembly positioning, analysis steps and output variables, contact constraints between the tool, the workpiece and the cutting fluid, and motion characteristics and loads of the tool and the cutting fluid.
Preferably, in step S1, the euler domain created is divided into a cutting fluid region and an empty region.
Preferably, in step S2, only the process of the tool cutting into the workpiece is calculated and analyzed.
Preferably, the output interval of the analysis step parameter of the pre-simulation model is set to 1, so that when the pre-simulation model is finished, the simulation can be performed subsequently using the secondary simulation model.
Preferably, in step S1, the euler domain range is the maximum range that the cutting fluid can reach during the simulation.
Preferably, in the grid division in the step S1, a contact area between the workpiece and the tool and a region with a preset width around the contact area adopt fine grids; coarse grids are adopted in other areas on the cutter and the workpiece; the euler domain uses a homogeneous grid.
Preferably, in step S3, the quadratic simulation model is subjected to computational analysis under the condition that the cutting fluid injection velocity is a positive number, and a simulation result is obtained. If the simulation result is not converged, the operation analysis is submitted again after the definition boundary conditions of the secondary simulation model are redefined until the simulation result is converged.
The invention has the beneficial effects that:
1. the invention constructs two same cutting simulation models, based on finite element analysis software, firstly uses the first cutting simulation model to perform dry cutting simulation on the process of cutting a tool into a workpiece, and then uses restart analysis to perform cutting simulation with cutting fluid jet speed by taking the simulation result of the first cutting simulation model as the initial state of the second cutting simulation model. If a traditional simulation mode is adopted, each model needs to be set with different working conditions of the cutting fluid and then is integrally operated to obtain an operation structure, but the method only needs to modify the working conditions of the cutting fluid in the secondary simulation model and carries out simulation on the basis of the first simulation model, so that the calculation amount of cutting simulation considering the cutting fluid is reduced; in addition, the invention can observe the conditions of chip breaking and temperature of different cutting fluid injection speeds by changing the cutting fluid injection speed, thereby realizing the optimization of the cutting fluid injection speed.
2. The invention uses finite element analysis software, takes cutting fluid addition as a basis, carries out simulation on the heat exchange and chip breaking functions of the cutting fluid, can obtain data which is difficult to obtain in an experiment, can predict the whole processing process and has high guiding value for practice.
3. The cutting simulation is carried out based on the coupled Euler Lagrange method, and the cutting simulation data obtained by adding the cutting fluid is truly displayed, so that the cutting fluid jet speed can be optimized in a simulation mode.
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FIG. 1 is a flow chart of the present invention.
FIG. 2 is a schematic diagram of a simulation model according to the present invention.
Reference numerals: in FIG. 1, 1-tool model; 2-a workpiece model; 3-cutting fluid.
Detailed Description
The following description of the embodiments of the present invention is provided by way of specific examples, and other advantages and effects of the present invention will be readily apparent to those skilled in the art from the disclosure herein. 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 is to be noted that the features in the following embodiments and examples may be combined with each other without conflict.
As shown in FIG. 1, a cutting fluid injection speed optimization method based on high-performance modeling simulation comprises the following steps:
step S1, preprocessing a cutting simulation model: aiming at a cutter, a workpiece and cutting fluid, constructing a thermal fluid coupling cutting simulation model, and defining parameters; parameters of the thermal coupling cutting simulation model comprise the range of an Euler domain, material properties, meshing, assembly positioning, creation of analysis steps and output variables, setting of a tool, contact constraint between a workpiece and cutting fluid, setting of motion characteristics and application of load to the tool and the cutting fluid.
As shown in fig. 2, a cutting simulation model with cutting fluid is established; the simulation model comprises a cutter model 1, a workpiece model 2 and an Euler domain 4; the euler field 4 is divided into a cutting fluid region 3 and an empty region. The tool, workpiece, euler domain and cutting fluid are modeled and divided in simulation software.
The modeling process of the cutting fluid is as follows: firstly, dividing a region where the cutting fluid is located in an established Euler domain, then giving material properties to the cutting fluid, and finally dividing the material region of the cutting fluid to establish the cutting fluid. In this embodiment, mm is selected as the unit for the length, and the units of the other parameters all use the same level dimension. After the three-dimensional models of the cutter, the workpiece, the Euler domain and the cutting fluid are completely established, material attributes are respectively defined for the three-dimensional models in simulation software so as to facilitate the simulation analysis of physical quantities.
Considering the performance of the cutter, the cutter is made of T15 powder metallurgy high-speed steel, the workpiece is GH 4169, and the cutting fluid is carbon nanotube-soybean oil nanofluid. The material parameters of the tool model, the workpiece model and the cutting fluid in the embodiment are shown in tables 1-3:
TABLE 1 tool Material parameters
TABLE 2 workpiece Material parameters
TABLE 3 cutting fluid Material parameters
The stress-strain relationship of GH 4169 steel is described by using a J-C model, which is shown as the following two formulas:
wherein σ JC The material uniaxial tension hot-sticking elastoplasticity rheological stress obtained for the traditional hot-sticking elastoplasticity J-C constitutive equation; ε is the strain;
is the strain rate;
is a reference strain rate; t is a unit of 0 Is a reference temperature; t is melt Is the material melting temperature of the workpiece; a, B, C, n and m are constants;
representing a dimensionless plastic strain rate; t is * ＝(T-T r )/(T m -T), representing a dimensionless temperature;
representing three degrees of stress, σ m In order to be under the stress of the ball,
is the Mises equivalent stress.
The specific parameters of the J-C model are shown in tables 4 and 5:
TABLE 4J-C constitutive model parameters of GH 4169 steels
TABLE 5J-C Damage model parameters for GH 4169 steels
The contact area of the cutter model and the workpiece model adopts fine grids, and the area of the cutter model and the workpiece far away from the contact area adopts coarse grids; the euler domain employs a homogeneous grid. And assembling and positioning the tool model, the workpiece model and the Euler domain of the divided grids. Selecting a realistic analysis step according to the cutting motion characteristics, and setting the output interval of parameters of the analysis step to be 1; furthermore, the cutting force during turning is defined in historical variables, and displacement, stress, strain, temperature are defined in field variables. And then the friction and the restriction between the cutter, the workpiece and the cutting fluid are defined according to the contact characteristics of the cutter, the workpiece and the cutting fluid. The invention mainly focuses on the heat exchange between the cutter and the cutting fluid in the cutting process and the chip breaking condition, so that the cutter is set as a rigid body, the analysis and calculation time can be reduced, and the accuracy of the calculation result can be improved. According to the contact state between the tool and the workpiece after the tool and the workpiece are cut, a modified Coulomb friction law is applied to define the friction characteristic between the tool and the workpiece, and the friction coefficient f =0.24. Then, boundary conditions of six direction constraints of the ground are applied to the workpiece model; controlling the movement of the cutter, and applying displacement constraint to the X direction; the Euler area distributes the area of the cutting fluid and controls the cutting fluid and the cutter to move together; in addition, the cutting force in the cutting process defined in the historical variable is only required to be output according to the tool reference point; displacement, stress, strain, temperature are defined in the field variables, and the output of the field variables is for the entire three-dimensional model.
And S2, submitting the thermal fluid coupling cutting simulation model to a simulation software solver to perform operational analysis based on a coupling Euler Lagrange method under the condition that the cutting fluid jet speed is zero, so as to obtain a simulation result. Only the calculation and analysis tool model 1 starts an analysis step process from cutting into the workpiece model 2, and does not calculate a process of cutting out the workpiece model 2 from the tool model 1.
The simulation results include cutting force, stress, strain, and temperature. And if the simulation result is not converged, re-entering the step S1, and adjusting the parameters of the thermal coupling cutting simulation model, specifically, changing the simulation model and finding the most appropriate cutting process parameter combination through the precise grid, the cutting force, the material damage and the temperature.
In the embodiment, the contact area of the tool and the workpiece and the preset range around the contact area are precise grids during simulation, and the rest parts of the tool and the workpiece are coarse grids; the euler domain employs homogeneous meshing. During the cutting process, the workpiece model is clamped on the machine tool through the clamp, so the bottom surface of the workpiece model is regarded as completely fixed, and the full-constraint boundary condition is applied to the bottom surface of the workpiece model during finite element simulation.
The process of adding the cutting fluid in the metal processing is simulated by simulation software, the temperature of a cutter, the temperature of a workpiece and the situation of chip breaking need to be concerned, the simulation step is divided into two steps in order to reduce the calculated amount, and the cutting fluid injection speed can be optimized only by replacing the cutting fluid injection speed in the model in the second step.
S3, taking the cutting simulation model obtained in the S1 and the S2 as a pre-simulation model; copying a pre-simulation model as a secondary simulation model; and restarting the secondary simulation model, and taking the simulation result of the pre-simulation model as the initial state of the secondary simulation model. Resetting the constraint parameters of the cutting fluid in the secondary simulation model; the constraint parameters of the cutting fluid are that the cutting fluid moves along with the cutter and is sprayed to the contact area of the cutter and the workpiece at a set spraying speed, so that the aims of chip breaking and heat exchange are fulfilled.
And S4, submitting the secondary simulation model to a simulation software solver, and performing operational analysis based on a coupled Euler Lagrange method by taking the terminal point of the pre-simulation model as a starting point to obtain a simulation result including cutting force, stress, strain and temperature. Analyzing and evaluating the simulation result; and if the simulation result is not converged, returning to the steps from S1 to S3, and adjusting the cutting simulation model. Since the convergence check has been performed on the cutting simulation model in step S2; therefore, only the quadratic simulation model for adjusting the cutting fluid injection speed can be converged with high probability.
Different cutting fluid injection speeds are set in the secondary simulation model, so that the influence of the different cutting fluid injection speeds on the cutting machining quality is obtained, and the optimal cutting fluid injection speed is selected according to the specified working condition.
The simulation method of the invention is different from the conventional simulation, which has large and rough calculation amount and only needs to divide the simulation steps into two steps. Establishing a simulation model in the first step, setting parameters of an Euler domain, a workpiece and a cutter and a constrained thermodynamic-fluid coupling model, and setting the jet speed of cutting fluid to be zero; and then, in the second step, restarting analysis is carried out by setting different cutting fluid jet velocities, and the second step is started on the basis of the first step, so that the purposes of reducing calculated amount by using restarting analysis, processing cutting simulation of large deformation based on a coupling Euler Lagrange method and carrying out cutting simulation by using thermal fluid coupling are realized, and the optimization of the cutting fluid jet velocity is realized.
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 thereto. Various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. A cutting fluid injection speed optimization method based on high-performance modeling simulation is characterized by comprising the following steps: the method comprises the following steps:
s1, constructing a thermal-hydraulic coupling cutting simulation model comprising a cutter, a workpiece and an Euler area, and performing grid division, assembly positioning, euler material area distribution and parameter setting;
s2, submitting the thermal fluid coupling cutting simulation model to operational analysis under the condition that the cutting fluid jet speed is zero to obtain a simulation result; if the simulation result is not converged, adjusting the parameters of the thermodynamic liquid coupling cutting simulation model and then submitting the parameters to operational analysis again until the simulation result is converged;
s3, taking the cutting simulation model obtained in the S1 and the S2 as a pre-simulation model; copying a pre-simulation model as a secondary simulation model; restarting and setting the secondary simulation model, and taking the simulation result of the pre-simulation model as the initial state of the secondary simulation model; resetting the constraint parameters of the cutting fluid in the secondary simulation model; the constraint parameter of the cutting fluid is that the cutting fluid is sprayed to the contact area of the cutter and the workpiece at a set spraying speed while moving along with the cutter;
and S4, setting a plurality of different cutting fluid jet speeds, submitting the secondary simulation models to operation analysis respectively to obtain simulation results corresponding to the different cutting fluid jet speeds, evaluating the influence of the cutting fluid jet speed on the metal processing performance according to the difference of the simulation results, and selecting the cutting fluid jet speed used in the processing.
2. The cutting fluid injection speed optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: in step S1, the established euler domain is divided into a cutting fluid region and an empty region.
3. The cutting fluid injection rate optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: in step S2, only the process of cutting the tool into the workpiece is calculated and analyzed.
4. The cutting fluid injection rate optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: the output interval of the analysis step parameters of the pre-simulation model is set to be 1, so that the secondary simulation model can continue to simulate after the pre-simulation model is finished.
5. The cutting fluid injection rate optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: in the step S1, the Euler domain range is the maximum range which can be reached by the cutting fluid in the simulation process.
6. The cutting fluid injection rate optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: in the grid division in the step S1, a contact area of the workpiece and the cutter and an area with a preset width around the contact area adopt fine grids; coarse grids are adopted in other areas on the cutter and the workpiece; the euler domain employs a homogeneous grid.
7. The cutting fluid injection rate optimization method based on the high-performance modeling simulation is characterized by comprising the following steps of: in the step S3, submitting the secondary simulation model to operational analysis under the condition that the cutting fluid jet velocity is a positive number to obtain a simulation result; if the simulation result is not converged, the operation analysis is submitted again after the definition boundary conditions of the secondary simulation model are redefined until the simulation result is converged.
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| CN117311889B (en) * | 2023-11-28 | 2024-04-09 | 中汽研汽车检验中心(广州)有限公司 | Simulation result display method, electronic device and storage medium |
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