考虑铲钻刀具倒棱刃口几何参数的钻削力理论模型

doi:10.12382/bgxb.2022.0753

摘要/Abstract

摘要：

为铲钻倒棱刃口的设计、开发和应用提供参考,建立考虑倒棱刃口几何参数的铲钻钻削力模型。基于正交切削理论,引入材料因刃口挤压产生形变的几何系数,建立倒棱刃口铲钻相对于主切削刃方向的切向力和法向力模型,根据铲钻切削刃的实际加工计算出铲钻的轴向力和扭矩。考虑分屑槽对铲钻钻削力的影响,使用变形系数代替剪切角和摩擦系数。采用有限元模拟铲钻钻削过程,进行铲钻的钻削力测试实验,得到铲钻的轴向力、扭矩,并将倒棱刃口铲钻的钻削力与锋利刃口的钻削力进行对比。研究结果表明:建立的钻削力理论公式适用于计算倒棱刃口铲钻轴向力和扭矩的计算,得到了倒棱刃口宽度和角度对铲钻钻削力的影响规律;设计铲钻刀具倒棱刃口时,铲钻刃口的倒棱宽度选择0.1mm,倒棱角度选择10°或30°可以获得较低的钻削力。

关键词: 铲钻刀具, 倒棱刃口, 钻削力, 理论模型

Abstract:

To provide reference for the design, development and application of the chamfered edge of the spade drill, the drilling force model of the spade drill considering the geometric parameters of the chamfered edge was established. Based on the orthogonal cutting theory, the geometric coefficient of the workpiece material deformation due to extrusion of the chamfered edge was introduced. The tangential force and normal force models of the chamfered spade drill relative to the direction of the main cutting edge were established. The axial force and torque of the spade drill were calculated according to the actual machining of its cutting edge. Considering the influence of the chip-split grooves on the drilling force of the spade drill, the deformation coefficient was used instead of shear angle and friction coefficient. The finite elements were employed to simulate the spade drilling process. The drilling force of the spade drill was tested experimentally. The axial force and torque of the spade drill were obtained. The drilling force of the spade drill with chamfered edge was compared with the drilling force of the ool with sharp cutting-edge. The results show that: the theoretical formula of drilling force established is suitable for calculating the axial force and torque of spade drills with chamfered edges; the influence law of the geometric parameters of the chamfer edge to the drilling force of the spade drill was obtained; when designing the chamfered edge of spade drills, the chamfer width of the spade drill should be 0.1mm, and the chamfer angle should be 10° or 30° to obtain a low drilling force.

Key words: spade drilling tools, chamfered edges, drilling force, theoretical model

王贵林, 于爱兵, 邹翩, 李毅, 李克凡, 吴森凯. 考虑铲钻刀具倒棱刃口几何参数的钻削力理论模型[J]. 兵工学报, 2023, 44(6): 1733-1743.

WANG Guilin, YU Aibing, ZOU Pian, LI Yi, LI Kefan, WU Senkai. Theoretical Model of Drilling Force Considering Geometrical Parameters of Chamfered Edge of Spade Drill[J]. Acta Armamentarii, 2023, 44(6): 1733-1743.

图/表 15

图1 铲钻刀片及倒棱刃口剖面图

Fig.1 Sectional drawing of spade drill insert and chamfered edge

表1 钻削实验的铲钻刀片倒棱刃口参数

Table 1 Chamfered edge parameters of spade drill inserts in drilling experiments

刀具编号	b/mm	γ/(°)	刀具编号	b/mm	γ/(°)
0	0	0	5	0.2	20
1	0.1	10	6	0.3	20
2	0.2	10	7	0.1	30
3	0.3	10	8	0.2	30
4	0.1	20	9	0.3	30

图2 钻削力测试实验装置

Fig.2 Drilling force test experimental devices

图3 钻削模型的边界条件和网格

Fig.3 Boundary conditions and meshes of the drilling model

表2 7075-T651铝合金的Johnson-Cook材料参数[16]

Table 2 Johnson-Cook material parameters of 7075-T651alloy[16]

A/MPa	B/MPa	n	C	m	$ε · 0$ /s^-1	T₀/℃	T_m/℃	d₁	d₂	d₃	d₄	d₅
527	575	0.72	0.017	1.61	1	25	635	0.110	0.572	-3.446	0.016	1.099

表2 7075-T651铝合金的Johnson-Cook材料参数[16]

Table 2 Johnson-Cook material parameters of 7075-T651alloy[16]

A/MPa	B/MPa	n	C	m	$ε · 0$ /s^-1	T₀/℃	T_m/℃	d₁	d₂	d₃	d₄	d₅
527	575	0.72	0.017	1.61	1	25	635	0.110	0.572	-3.446	0.016	1.099

表3 7075-T651铝合金的热性能和力学性能[17]

Table 3 Thermal and mechanical properties of 7075-T651 alloy[17]

温度/℃	导热系数/(W·m^-1·℃^-1)	密度/(kg·m^-3)	杨氏模量/GPa	热膨胀系数/℃^-1	比热/(J·kg^-1·℃^-1)	泊松比
25	130	2810	71.1	2.16×10^-5	870	0.33
100	186	2800	65.2	2.34×10^-5	910	0.33
200	197	2770	56.3	2.36×10^-5	960	0.33
300	194	2750	38.0	2.43×10^-5	980	0.33
400	196	2730	31.5	2.52×10^-5	1040	0.33
500	196	2700	25.0	2.61×10^-5	1100	0.33
532	193	2690	24.0	2.75×10^-5	1110	0.33

表4 硬质合金铲钻刀片的材料参数[18]

Table 4 Material parameters of carbide spade drill inserts[18]

导热系数/(W·m^-1·℃^-1)	密度/(kg·m^-3)	杨氏模量/GPa	热膨胀系数/℃^-1	比热/(J·kg^-1·℃^-1)	泊松比
79.6	14850	640	4.7×10^-6	176	0.22

图4 第1变形区下边界理想轮廓的受力分析

Fig.4 Force analysis of the ideal contour of the lower boundary of the primary deformation zone

图5 工件材料在铲钻倒棱刃口的流动模式

Fig.5 Flow pattern of workpiece material on the chamfered edge of the spade drill

图6 铲钻切削刃单元dW的钻削力分量

Fig.6 Drilling force component of the cutting edge unit dW of the spade drill

图7 铲钻分屑槽工作原理示意图

Fig.7 Schematic diagram of the working principle of the chip-split grooves of the spade drill

表5 理论模型参数

Table 5 Values of theoretical model parameters

参数	刀具编号
参数	1	2	3	4	5	6	7	8	9
ξ	1.58	1.75	1.90	1.53	1.69	1.80	1.60	1.80	2.03
c	0.046	0.030	0.023	0.102	0.057	0.036	0.06	0.031	0.039

图8 模拟、计算和钻削实验的轴向力和扭矩

Fig.8 Axial forces and torques from simulation, theory and drilling experiment

图9 锋利刃口和倒棱刃口铲钻轴向力和扭矩的对比

Fig.9 Comparison of axial force and torque between spade drills with sharp cutting-edge and chamfered edge

图10 倒棱刃口相对于锋利刃口铲钻轴向力和扭矩增长率

Fig.10 Growth rates of axial force and torque of spade drill with chamfered edge relative to that with sharp cutting-edge

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