تحليل المان محدود فرآيند براده برداري با نرم افزار Deform-3D و بررسي سايش ابزار

چكيده انگليسي :

Finite Element Analysis of Machining with Deform 3D and Investigation of Tool Wear Mohamad Rezaie Rajaie Email address m rezaierajaie@me iut ac ir Date of Submission 5th march 2012 Department of Mechanical Engineering Isfahan University of Technology Isfahan 84156 83111 Iran Degree M Sc Language Farsi Supervisor s Name Mehran Moradi Assistant Professor moradi@cc iut ac irAbstractTurning process as a common machining process to produce cylindrical shape parts is one of the most commonmanufacturing processes for producing parts of desirable dimensions It is used to remove unwanted materialfrom a workpiece and obtain specified geometrical dimensions and also surface finishing Understanding of material removal concepts in metal cutting is very important in design process and cutting toolselection to ensure the quality of the products Since experimental investigation on the field of metal cutting isexpensive and has a high time cost and a lot of limits today researchers have applied the finite element methodfor their investigations Recently tool wear that has important role in quality of machined surface and economyof production has been surveyed in the investigation by the finite element method In metal cutting tool wear onthe tool chip and tool workpiece interfaces i e flank wear and crater wear is strongly influenced by the cuttingtemperature contact stresses and relative sliding velocity at the interface These process variables depend on tooland workpiece materials tool geometry and coatings cutting conditions and use of coolant for the givenapplication Based on temperatures and stresses on the tool face predicted by the finite element analysis FEA simulation tool wear may be estimated with acceptable accuracy using an empirical wear model According tothe technical literature several wear mechanisms can be defined namely abrasion related to thermo mechanicalaction adhesion related to micro welding and Built Up Edge formation and removal diffusion chemicalalteration due to atomic migration at high temperature and fatigue The above phenomena are generally presentin combination even if one or few of them are dominant depending on the cutting parameters and tool workpiece combination For this reason it is very difficult to define a general effective criterion for tool wear because the proposed models are focused on some of the main wear mechanisms only In this study Deform 3D finite element software was used to simulate the cutting process turning and a suitablesubroutine was implemented into the software in order to predict the tool wear In the first of this research withuse of three empirical tool wear models usui model takeyama model and coupled abrasive diffusive wearmodel crater wear on tool rake face is predicted Then simulation results are compared to experimentalmeasurement in order to introduce best wear rate model coupled abrasive diffusive wear model is introduced asthe best wear rate model In the second part of this research coupled abrasive diffusive wear model has beenemployed in order to predict crater wear in different cutting parameters cutting speed feed rate depth of cut anddifferent tool geometry rake angle entering angle and tool nose radius Then effect of cutting parameters andcutting tool geometry on the tool wear are investigated with use of analysis of variance ANOVA Analysis ofANOVA for crater wear on the tool rake face revealed that cutting speed have most influence on the tool wearand then feed rate tool nose radius and depth of cut respectively have most influence on the tool wear Influenceof rake angle and entering angle is low on the tool wear Key wordsMachining turning tool wear finite element analysis of variance

رضايي رجايي، محمد

تحليل المان محدود فرآيند براده برداري با نرم افزار Deform-3D و بررسي سايش ابزار

ماشينكاري , طراحي آزمايش , آناليز واريانس