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Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

机译:鼻径半径对AISI-4140硬转弯期间诱导的加工力的影响:基于CAD和3D FEM方法

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摘要

The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.
机译:本研究借助于3D有限元(FE)模型,研究了三种陶瓷插入件的性能,借助于3D有限元(FE)模型。根据预定义的切割和刀尖半径的预定深度和进料速率,根据三个水平进行九个模拟运行。将所得结果与用于验证目的相同的切削条件中获得的实验值进行比较。因此,进行了两组九个模拟,使得总共27个转向仿真运行将陷入困境。这两个额外的组对应于相同的切割条件,而是对不同的切削工具(具有不同的鼻径)。此外,基于诸如响应面方法(RSM)等统计方法建立预测模型以及方差分析(ANOVA),进一步研究了临界参数(切削速度,进料速率和鼻径)之间的关系及其对产生的转动力分量的影响。切割力分量和模拟分量的实验值之间的比较证明了超过89%的增加的相关性。类似地,由于验证的充分率,从统计模型导出的值符合等效的FE模型值。

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