ϕ0.75 mm深小孔微镗削刀具角度参数仿真优化分析

Simulation optimization analysis of angle parameters for ϕ0.75mm deep micro-boring tool

  • 摘要: 05Cr17Ni4Cu4Nb不锈钢活门座是航空发动机用燃油电磁阀的重要零件,活门座上控制燃油流量的深小孔(ϕ0.75 mm,深4 mm)尺寸要求严格。现加工用德国Horn硬质合金微镗刀为系列化进口采购,刀具尺寸较小、刚度较差,在加工时易产生振动,导致加工尺寸不合格,批量化产品的合格率低。文章采用优化刀具角度参数的方法来减小切削力,进而减小刀具的颤振。基于DEFORM 3D仿真软件建立深小孔微镗削的有限元模型,采用单因素实验法和正交实验法,探究刀具角度参数对切削力的影响规律,并选取最优的刀具角度组合。结果表明,在所选研究参数范围内,切削力大小随着前角、后角、主偏角、副偏角增大而减小;前角对切削力影响最大,后角最小,影响主次顺序为前角>主偏角>副偏角>后角;最优刀具角度组合为前角 \gamma _\mathrmo =6°,后角 \alpha _\mathrmo =7°,主偏角 \kappa _\mathrmr =95°,副偏角 \kappa '_\mathrmr =5°;优化后刀具加工深小孔时轴向力降低了66.90%,径向力降低了53.58%,切向力降低了40.69%;刀具最大颤振变形量降低了41.81%,刀具的轴向最大振幅降低了约44.67%,径向最大振幅降低了约39.84%,切向最大振幅降低了约41.80%;刀具颤振时刀尖位置处于允许尺寸范围内,能够有效提高产品的合格率。

     

    Abstract: 05Cr17Ni4Cu4Nb stainless steel valve seat is an important part of the fuel solenoid valve for aero engine, and the size of the deep hole (ϕ0.75 mm, depth 4 mm) to control the fuel flow on the valve seat is strict. Horn cemented carbide cutter for processing is small in size, poor in stiffness, and easy to vibrate during processing, resulting in unqualified processing size and low pass rate of batch products. The method of optimizing the tool angle parameters is used to reduce the cutting force, and thus the chatter of the tool. Based on DEFORM 3D simulation software, the finite element model of deep hole boring was established, and the influence of tool angle parameters on cutting force was explored by using single factor experiment method and orthogonal experiment method, and the optimal tool angle combination was selected. The results show that within the range of selected research parameters, the cutting force decreases with the increase of rake angle, clearance angle, cutting edge angle and minor cutting edge angle. The rake angle has the greatest influence on the cutting force, while the clearance angle has the smallest. The primary and secondary order of influence is the rake angle > cutting edge angle > minor cutting edge angle > clearance angle. The optimal tool angle combination is rake angle \gamma _\mathrmo =6°, clearance angle \alpha _\mathrmo =7°, cutting edge angle \kappa _\mathrmr =95°, minor cutting edge angle \kappa '_\mathrmr =5°. After optimization, the axial force is reduced by 66.90%, the radial force is reduced by 53.58%, and the tangential force is reduced by 40.69% when the tool is used to make deep holes. The maximum tool chatter deformation is reduced by 41.81%, the axial amplitude of the tool is reduced by about 44.67%, the radial amplitude by about 39.84%, and the tangential amplitude by about 41.80%. When the tool flutters, the position of the tool tip is within the allowable size range, which can effectively improve the pass rate of the product.

     

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