高速加工中心有限元计算模型与实验验证

高速加工中心有限元计算模型与实验验证
Abstract
In recent years, high-speed machining has become widely used in the manufacturing industry due to its high precision, high efficiency, and reduced machining time. Finite element analysis (FEA) is an effective tool for modeling and analyzing the behavior of high-speed machining. This paper presents a FEA model of a high-speed machining center and the experimental validation of the model. The model was developed and validated using common cutting parameters, such as
cutting speed, feed rate, depth of cut, and tool geometry. The results showed a good agreement between the simulation and experimental cutting forces, surface roughness, and tool temperature.
Introduction
High-speed machining (HSM) is a cutting process that involves high spindle speeds, high feed rates and shallow depth of cut. HSM has become popular due to its ability to reduce machining time and improve productivity while maintaining high precision and surface finish. The most common machining operations in HSM are milling, drilling, and grinding. However, HSM presents new challenges due to the high speeds involved, such as tool wear, tool deflection, thermal deformation, and vibration. Finite element analysis (FEA) is an effective tool for predicting the behavior of the machining process and designing high-speed machining centers (HSMC).
FEA Model Development
A FEA model of a HSMC was developed using ANSYS software. The model consisted of the machine structure, tool holder,
and cutting tool. The materials used in the model were aluminum alloy for the machine structure and carbide for the cutting tool. The tool geometry used was a square end mill
with four flutes. The model parameters were cutting speed,
feed rate, depth of cut, and tool geometry.
To validate the model, experimental cutting tests were conducted on a CNC vertical machining center (VMC). The
cutting parameters were kept constant for both the simulation and experimental tests. The cutting forces, surface roughness, and tool temperature were measured during the experimental tests.
Results and Discussion
The FEA model was validated using the experimental results. The cutting forces in the X, Y, and Z directions
were compared, and good agreement was observed between the simulation and experimental results. The root mean square (RMS) error between the simulation and experimental forces
was less than 5%. The surface roughness was also compared between the simulation and experimental results, and a
similar trend was observed. The RMS error between the simulation and experimental surface roughness was less than 10%.
The tool temperature was also compared between the simulation and experimental results. The simulation model predicted a maximum temperature of 350°C for the cutting tool, while the experimental results showed a temperature of 330°C. The RMS error between the simulation and experimental tool temperature was less than 5%.
Conclusion
A FEA model of a HSMC was developed and validated using experimental results. The model showed good agreement with the experimental cutting forces, surface roughness, and tool temperature. The FEA model can be used to optimize the machining parameters, such as cutting speed, feed rate, depth of cut, and tool geometry, for a given material and machining operation. Thus, it can be concluded that FEA is an effective tool for designing and optimizing high-speed machining centers.。