Ceramic Cutting Tool Speed Finite Element Analysis - Tools, Tool Technology, Hardware - Hardware

1 Functionally Gradient Ceramic Tools Three-dimensional Machinery Stress Calculation Model

Functionally gradient ceramic tools because of its composition changes in the distribution of a certain gradient, so under the conditions of high speed cutting ability of the anti breakage than ordinary ceramic tools has improved significantly. But in low speed cutting, functionally gradient ceramic tool capacity and resistance to breakage than ordinary ceramic tool is not much advantage. Low-speed cutting smaller thermal stress, mechanical stress is the main tool breakage. Finite element method by cutting the time of the analysis of functionally gradient ceramic tools can be obtained and the mechanical stress.

Figure 1 shows the calculation model for the mechanical stress. Place knife blade slot, knife blade bottom surface binding negative z-axis displacement of blade rake face of the plate bound z-axis positive displacement blade, knife blade slot of the two side constraints of x and y to the displacement, surface and bottom knife blade around the plate also limited x-axis and y-axis spin, knife blade around the slot limit the sides of z axis. In this way, the blades 6 degrees of freedom are all bound.

In the cutting process, the tool has to withstand the cutting forces Fr FZ, Fy and Fx three components. As a result of the finite element method calculation of cutting force to be applied at all nodes, it assumes that the cutting force along the knife? Chip contacting length of the triangular distribution, while along the main and auxiliary cutting edge direction is uniformly distributed. By a document known, SG-4 ceramic cutting tools in machining hardened high-carbon Tool Steel cutting force when the empirical formula for the Fz = 34444ap0.88f0.65v-0.12 (1)

Assume that FY = 0.5Fz (2) FX = 0.8Fz (3) Table 1, two kinds of ceramic cutting tools in a variety of cutting speeds of three-dimensional cutting force component value v (m / min) 50100150Fz (N) 74.968.965.4FX (N) 59.955.152.3FY (N) 37.534.532.7

Table 1 for the FG-2 functionally gradient ceramic tool (assuming equation (1) ~ (3) also applies to the FG-2) and SG-4 ordinary ceramic cutting tools in a variety of cutting speeds of three-dimensional cutting force component value. Among them, the cutting speed were taken v = 50m/min, v = 100m/min, v = 150m/min, feed rate f = 0.05mm / r, back knife to eat the amount ap = 0.2mm, the workpiece material for the T10A (hardness 59.5 HRC). FG-2 levels in the physical properties of Table 2 (SG-4 of the physical properties of the first layer of FG-2 the same).

Far as clamping tip dot pitch, the clamping force on the stress state near the tip has little effect, so from time to consider the impact of clamping force; same time, because the surface of ceramic blade is smooth, the friction coefficient is small, so clamping the friction effect can not be considered. Measure of material damage theory of maximum tensile stress (Principal) theory, the maximum shear stress (Tresca) theory, the maximum distortion energy (Mises) theory, the Mohr theory. Fatigue failure for brittle materials the maximum stress theory should be adopted and the maximum shear stress theory; for brittle material ductile failure should adopt the maximum distortion energy theory. Functionally gradient ceramic tools for high-speed cutting, the existing fatigue damage, but also the plastic tip temperature is too high causing damage, it should be calculated within the functionally gradient ceramic tool maximum stress, maximum shear stress and the maximum shape change energy (Mises) stress. Table 2FG-2 levels the proportion of the physical properties of layer number r

(G? Cm-3) thermal conductivity k (20 )

[W? (MK) -1] the specific heat C (20 )

[Cal? (GK) -1] thermal expansion coefficient a (20 )

( 106/K-1) elastic modulus E

(GPa) Poisson's ratio v45.66635.160.1277.660424.70.2423/55.9434.350.1217.522432.60.2392/66.2233.550.1157.386440.70.2351/76.5032.770.1107.251448.90.232

by: gaga

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