含断屑块PCD刀具主偏角对切屑流向的影响

doi:10.12382/bgxb.2023.1051

摘要/Abstract

摘要：

合理选用刀具角度能够提高含断屑块聚晶金刚石(Polycrystalline Diamond,PCD)刀具的切屑控制效果。用有限元模拟和高速摄影观察切削过程,分析主偏角对切屑流向的影响规律。提出切屑接触率的概念用来衡量断屑块对切屑流向的影响程度,收集并统计切屑类型,建立主偏角与切屑接触率之间的关系曲线,确定主偏角的合理取值范围。提出断屑块偏转角度参数,建立偏转角与切屑接触率之间的关系曲线。研究结果表明:增大主偏角会减弱断屑块对切屑流向的控制作用;当主偏角范围为75°~ 95°时,切屑能够流向工件表面并折断形成C形、6形和紧凑型短螺旋切屑;通过调整断屑块偏转角可以改善非合理主偏角切削条件下的断屑效果;选用合理的主偏角和断屑块偏转角度,能够提高含断屑块PCD刀具的切屑接触率,实现有效断屑,提高优良切屑比例。

关键词: 聚晶金刚石刀具, 切屑流向, 断屑, 主偏角

Abstract:

A tool angle can be reasonably selected to improve the chip control effect of polycrystalline diamond (PCD) tools with chip breakers. The cutting process is observed by finite element simulation and high-speed photography, and the influence of cutting edge angle on chip flow direction is analyzed. A concept of chip contact rate is put forward to measure the influence of chip breaker on chip flow direction, the types of chip are collected and counted, the relation curve between cutting edge angle and chip contact rate is established, and the reasonable value range of cutting edge angle is determined. The deflection angle parameters of chip breaker are presented, and the relation curve between the deflection angle and the chip contact rate is established. The results show that the increase in the cutting edge angle will weaken the control effect of chip breaker on the chip flow direction. When the cutting edge angle is in the range of 75°- 95°, the chip can flow to the workpiece surface and break to form C-shaped, 6-shaped and compact short spiral chips. and the chip breaking effect under the condition of unreasonable cutting edge angle can be improved by adjusting the chip deflection angle. Selecting the reasonable cutting edge angle and chip breaker deflection angle can improve the chip contact rate of PCD tool with chip breaker, realize the effective chip breaking and improve the excellent chip ratio.

Key words: polycrystalline diamond tool, chip flow direction, chip breaking, cutting edge angle

中图分类号:

TG712

王家炜, 于爱兵, 李毅, 叶家往, 赵家震, 齐少春. 含断屑块PCD刀具主偏角对切屑流向的影响[J]. 兵工学报, 2024, 45(12): 4488-4499.

WANG Jiawei, YU Aibing, LI Yi, YE Jiawang, ZHAO Jiazhen, QI Shaochun. Effect of Cutting Edge Angle of PCD Tool with Chip Breaker on Chip Flow[J]. Acta Armamentarii, 2024, 45(12): 4488-4499.

图/表 17

图1 含断屑块PCD刀具

Fig.1 PCD tool with chip breaker

图2 有限元切削模型

Fig.2 Finite element cutting model

表1 7075-T651铝合金的J-C材料参数[16-17]

Table 1 J-C material parameters of 7075-T651 aluminium alloy[16-17]

参数	取值
弹性模量/GPa	71.7
泊松比	0.33
熔点/K	908
比热容/(J·kg^-1·K^-1)	0.786T+839.2
热导率/(W·m^-1·K^-1)	-0.0002T²+0.1366T+128.63
热膨胀系数/(μm·m^-1·K^-1)	25.2
密度/(kg·m^-3)	2810
A/MPa	527
B/MPa	575
n	0.72
c	0.017
m	1.61
$ε · 0$	1
T₀	25
T_m	635
D₁	0.110
D₂	0.572
D₃	-3.446
D₄	0.016
D₅	1.099

表1 7075-T651铝合金的J-C材料参数[16-17]

Table 1 J-C material parameters of 7075-T651 aluminium alloy[16-17]

参数	取值
弹性模量/GPa	71.7
泊松比	0.33
熔点/K	908
比热容/(J·kg^-1·K^-1)	0.786T+839.2
热导率/(W·m^-1·K^-1)	-0.0002T²+0.1366T+128.63
热膨胀系数/(μm·m^-1·K^-1)	25.2
密度/(kg·m^-3)	2810
A/MPa	527
B/MPa	575
n	0.72
c	0.017
m	1.61
$ε · 0$	1
T₀	25
T_m	635
D₁	0.110
D₂	0.572
D₃	-3.446
D₄	0.016
D₅	1.099

表2 PCD刀具的物理特性[17]

Table 2 Physical properties of PCD tool[17]

参数	数值
弹性模量/GPa	900
泊松比	0.1
比热容/(J·kg^-1·K^-1)	471.5
导热系数/(W·m^-1·K^-1)	100
密度/(kg·m^-3)	3500

图3 切屑对比

Fig.3 Chip contrast

图4 含断屑块刀具在不同主偏角下的仿真结果

Fig.4 Simulated results of PCD tool with chip breaker at different cutting edge angles

图5 切屑折断情况

Fig.5 Chip breaking condition

图6 PCD刀具在不同主偏角条件下的切削形成过程高速摄影

Fig.6 High-speed photography of the cutting process of PCD tool at different cutting edge angles

表3 流屑角、扭转角的仿真与实验结果对比

Table 3 Comparison of analyzed and experimental results

κ_r	ψ_λ/(°)			η/(°)
κ_r	实验值	仿真值	相对误差/%	实验值	仿真值	相对误差/%
90	11	10	9.09	23	20	13.04
95	16	15	6.25	15	16	6.67
105	29	33	13.79	11	10	9.09

图7 切屑卷曲过程

Fig.7 Chip curling process

图8 含断屑块刀具在不同主偏角下产生的切屑形状

Fig.8 Chip shapes produced by tools with chip breaker at differentcutting edge angles

图9 各类切屑的比例

Fig.9 The proportion of all kinds of chips

图10 含断屑块PCD刀具的S-κr关系曲线

Fig.10 S-κr relationship curve of PCD tool with chip breaker

图11 断屑块参数示意图

Fig.11 Schematic diagram of chip breaker parameters

图12 断屑块偏转角度示意图

Fig.12 Schematic diagram of deflection angle of chip breaker

图13 含断屑块PCD刀具的S-αr关系

Fig.13 S-αr relationship curve of PCD tool with chip breaker

图14 不同断屑块偏转角下的切屑形状

Fig.14 Chip shape at different deflection angles of chip breaker

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