刀具磨损的偏最小二乘回归分析与建模

简述了偏最小二乘回归方法;对在不同切削条件下车削加工过程刀具后刀面磨损的多组实验数据,采用偏最小二乘回归方法,根据变量重要性指标分析和因子载荷分析,从8个变量及其组合中筛选出了6个用于建模的自变量,并以后刀具磨损量作为因变量,建立了对所选自变量(切削速度V、切削分力的均值F_x、F_y和F_z、分力比值F_y/F_x和F_z/F_x等)的偏最小二乘回归模型;采用建模数据覆盖的切削条件下的实验数据和建模数据未覆盖的切削条件下的实验数据,分别对模型进行了验证.结果表明,采用偏最小二乘回归方法选择的自变量是合理的,所建立的刀具磨损的回归模型可以较满意地计算出不同切削条件下刀具后刀面的磨损量.     

DLC涂层硬质合金微钻的制备及其切削性能

在硬质合金微型刀具加工高硅铝合金等难加工材料时,通过采用改进的热丝CVD装置开展了DLC涂层硬质合金微钻制备工艺优化,得到了最优沉积工艺,并配合高速加工高硅铝合金(Si15%)材料微小孔钻削性能对比试验,分析了刀具的磨损机理.结果表明:两步预处理方法适合复杂形状硬质合金衬底的预处理方法.钻削高硅铝合金时,DLC涂层具有低摩擦系数和高耐磨损特性,同等切削条件下,涂层微钻的切削寿命比未涂层硬质合金微钻提高了10倍.     

高速钻削复合材料的切削力

采用多种硬质合金钻头,在高转速和不同进给速度条件下对碳纤维/环氧树脂复合材料进行孔加工正交试验,通过研究其轴向力和扭矩以分析刀具条件和切削参数的适应性.结果表明:主轴转速是影响轴向力和扭矩的最主要因素,高转速钻削时轴向力和扭矩都显著减小;减小进给速度也使轴向力和扭矩减小,但其影响小于主轴转速.此外,钻头材质对轴向力和扭矩的影响大于钻头几何形状和进给速度;进给速度对轴向力的影响较大,而钻头几何形状对扭矩的影响较大.     

微小孔加工试验及刀具磨损机理

由于钛合金和印刷电路板的难加工性使得微小孔的加工精度和表面质量难以保证,刀具技术成为提高加工效率的主要障碍。本文应用3种不同涂层钻头对钛合金和印刷电路板进行微小孔钻削对比试验,研究了进给速度与切削力和扭矩的关系,分析了刀具的磨损特征以及孔的表面质量和孔入口处的毛刺情况。结果表明:钻削印刷电路板的临界进给速度为1 591.2 mm/m in,涂层对钻削力和扭矩的影响不明显;类金钢石(DLC)涂层硬质合金钻头比普通硬质合金钻头和T iC涂层硬质合金钻头更适合加工钛合金材料微小孔。     

加工钛合金大口径深盲孔的研究

钛合金属难加工材料,其深孔加工的难度更为突出,加工质量不易保证。本文通过实验对比,对加工钛合金大口径深盲孔中出现的偏孔、切屑堵塞、切削振动、刀具破损等主要问题进行了分析,提出了解决办法,得出了切削用量的优化参数。由于钛合金的化学亲和作用,深孔加工刀具的导向条表面易于粘附,结果拉伤已加工表面,造成表面粗糙度上升。加大导向条与孔壁的间隙虽可减少导向条表面的粘附,但同时会引起切削振动的加剧。针对这一矛盾,本文着重对加工刀具的导向条分布、导向条与孔壁的间隙以及导向条的选材方面进行了探讨,提出了以非金属导向条代替硬质合金导向条进行钛合金深孔精加工的方法,使得已加工表面的粗糙度大大降低。这些研究结果对实际加工具有一定的指导作用。     

刀具织构轮廓对碳纤维增强复合材料面下损伤影响的切削仿真研究

为减小碳纤维增强复合材料（CFRP）加工时的面下损伤深度,创建了基于二维Hashin准则的宏观连续动态切削CFRP有限元模型,分析了切削力和面下损伤深度与纤维方向角之间的变化趋势,通过引入织构刀具来降低切削力及面下损伤深度,比较了沟槽形织构刀具、圆形织构刀具、三角形织构刀具切削CFRP的切削力和面下损伤。结果表明,不同织构刀具的切削力和面下损伤深度随纤维方向角变化趋势一致,均在0°时最小,90°达到最大值;织构刀具相对传统无织构刀具切削CFRP时均降低了切削力和面下损伤深度,其中圆形织构刀具降低程度最大;仿真模型经实验验证准确有效。     

Cutting tool temperature prediction method using analytical model for end milling

Dramatic tool temperature variation in end milling can cause excessive tool wear and shorten its life, especially in machining of difficult-to-machine materials. In this study, a new analyt-ical model-based method for the prediction of cutting tool temperature in end milling is presented. The cutting cycle is divided into temperature increase and decrease phases. For the temperature increase phase, a temperature prediction model considering real friction state between the chip and tool is proposed, and the heat flux and tool-chip contact length are then obtained through finite element simulation. In the temperature decrease phase, a temperature decrease model based on the one-dimension plate heat convection is proposed. A single wire thermocouple is employed to mea-sure the tool temperature in the conducted milling experiments. Both of the theoretical and experi-mental results are obtained with cutting conditions of the cutting speed ranging from 60 m/min to 100 m/min, feed per tooth from 0.12 mm/z to 0.20 mm/z, and the radial and axial depth of cut respec-tively being 4 mm and 0.5 mm. The comparison results show high agreement between the physical cutting experiments and the proposed cutting tool temperature prediction method.     

挠性杆的镗加工技术

针对挠性杆的结构特点和加工难点,提出了有效的工艺措施,从装夹定位、刀具材料与几何参数选择、刃磨方法、切削用量的选择,以及挠性杆内应力的分析等方面详细地阐述了加工过程中的关键技术,解决了挠性杆镗削加工的技术难题。     

基于有限元方法的并联机床模态分析

并联机床的模态分析有着重要的意义。本文针对3—HSS型并联机床,利用大型有限元软件ANSYS,对此并联机床进行了模态分析,分别获得了该机床的低阶固有频率及其对应的振型图,通过振动动画,分析了六阶模态的振动规律,找到了机床的薄弱环节,为机床的结构设计和动力学分析提供了依据。     

Predictive Modeling and Parameter Optimization of Cutting Forces During Orbital Drilling

To optimize cutting control parameters and provide scientific evidence for controlling cutting forces,cutting force modeling and cutting control parameter optimization are researched with one tool adopted to orbital drill holes in aluminum alloy 6061.Firstly,four cutting control parameters(tool rotation speed,tool revolution speed,axial feeding pitch and tool revolution radius)and affecting cutting forces are identified after orbital drilling kinematics analysis.Secondly,hybrid level orthogonal experiment method is utilized in modeling experiment.By nonlinear regression analysis,two quadratic prediction models for axial and radial forces are established,where the above four control parameters are used as input variables.Then,model accuracy and cutting control parameters are analyzed.Upon axial and radial forces models,two optimal combinations of cutting control parameters are obtained for processing a13mm hole,corresponding to the minimum axial force and the radial force respectively.Finally,each optimal combination is applied in verification experiment.The verification experiment results of cutting force are in good agreement with prediction model,which confirms accracy of the research method in practical production.