Numerical Simulation on Milling Process of Ni-based Alloy Welds and Optimization Analysis of Milling Cutter
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摘要: 为优化镍基合金焊缝铣削加工工艺与刀具性能，基于Abaqus仿真软件建立了镍基合金焊缝铣削的有限元模型，并进行了铣削过程的仿真计算分析及刀具失效研究，分析了不同切削参数和刀具参数对切削温度及切削力的影响，结合计算结果完成了切削参数正交试验与刀具参数优化分析。结果表明，较小的切削速度、小进给量及增加风冷可以获得较小的切削力和切削温度，通过调节刀具前角和刀尖钝圆半径可以有效降低切削力和切削温度。本研究成果可为铣削过程切削参数及刀具参数的优化提供参考。Abstract: In order to optimize the milling process and cutter performance of nickel-base alloy welds, the finite element model of nickel-base alloy weld milling was established based on Abaqus simulation software, and the milling process simulation calculation analysis and cutter failure research were carried out. The effects of different cutting parameters and cutter parameters on cutting temperature and cutting force were analyzed. Combined with the calculation results, the orthogonal test of cutting parameters and the optimization analysis of cutter parameters were completed. The results show that smaller cutting force and cutting temperature can be obtained with smaller cutting speed, small feed rate and increased air cooling, and the cutting force and cutting temperature can be effectively reduced by adjusting the cutter front angle and the blunt radius of the cutter tip. The research results can provide reference for the optimization of cutting parameters and cutter parameters in the milling process.
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Key words:
- Milling simulation /
- Numerical simulation /
- Cutting force /
- Cutting temperature.
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图 12 刀尖钝圆半径对铣削过程的影响规律
Figure 12. Effect of Blunt Radius of Cutter Tip on Milling Process
表 1 材料参数
Table 1. Parameters of Materials
参数 镍基合金 硬质合金 A/MPa 985 875 B/MPa 949 793 n 0.4 0.39 C 0.01 0.01 m 1.65 0.71 d1 0.04 −0.09 d2 0.75 0.25 d3 −1.45 −0.5 d4 0.04 0.014 d5 0.89 3.87 ${\dot{\varepsilon } }_{0}$ 0.001 0.028 
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表 2 因素水平表
Table 2. Factor Levels
切削速度/(m·s−1) 2.0 2.5 3.0 3.5 进给量/mm 0.06 0.08 0.10 0.12 表面换热系数/[W·(m2·K)−1] 20 30 40 50
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表 3 铣削工艺优化计算结果
Table 3. Calculation Results of Milling Process Optimization
序号 因素 切削
力/N切削
温度/℃切削速度/
(m·s−1)进给量/
mm表面换热系数/
[W·(m2·K)−1]1 2.0 0.06 20 257 490 2 2.0 0.80 30 316 553 3 2.0 0.10 40 348 547 4 2.0 0.12 50 471 536 5 2.5 0.06 30 289 469 6 2.5 0.08 20 301 479 7 2.5 0.10 50 357 532 8 2.5 0.12 40 501 611 9 3.0 0.06 40 307 487 10 3.0 0.08 50 346 511 11 3.0 0.10 20 493 679 12 3.0 0.12 30 513 736 13 3.5 0.06 50 311 483 14 3.5 0.08 40 364 609 15 3.5 0.10 30 499 682 16 3.5 0.12 20 634 864
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