Abstract
The simulation of coated tool milling natural marble is constructed based on Deform-3D. The influence mechanism of machining parameters on cutting force is analyzed. The results show that the error between cutting forces of simulation and experiment is within 10%, suggesting the reliability of the simulation results. According to the study, the cutting force decreases along with the increase of spindle speed while the downtrend of cutting force slows down because of workpiece work-hardening when spindle speed reaches around 3000-5000 r/min; the cutting force linearly increases with the changes of cutting depth due to the increase of axial cutting quantity; the cutting force increases as the increase of feed speed below 3000 mm/min. Once feed speed reaches to 3000 mm/min, the brittle-ductile transition appears, resulting in redistribution on the surface which decreases the real cutting force; The empirical equation of cutting force is obtained through experimental data, which indicated that large spindle speed and feed speed, small cutting depth can reduce cutting force; the appearance of brittle-ductile transition will increase the surface quality and thus improve cutting performance of coated tool.DOI: http://dx.doi.org/10.5755/j01.mech.22.4.16160
Highlights
Natural marble is a typical brittle material that is easy to generate incontrollable brittle fracture in practical machining; it intensifies the tool wear and decreases processing efficiency [1]
Natural marble milling process was simulated based on Deform-3D in this paper; the milling force data obtained by simulation and experiment were compared
The milling process simulation of natural marble based on Deform-3D was carried out in this paper
Summary
Natural marble is a typical brittle material that is easy to generate incontrollable brittle fracture in practical machining; it intensifies the tool wear and decreases processing efficiency [1]. The finite element simulation has become a very effective method in the research of cutting characteristics and optimization process [3]. Yuan Juntang took the simulation of aluminum alloy cutting process by Deform-3D and study change rule of the milling force [4]. Cong Ming carried out the simulation research of drilling process of engine cylinder block through Deform-3D and optimized the cutting parameters. Cutting force is a main reason of tool wear and workpiece brittle fracture during the high speed milling process of natural marble. Cutting force is an important composition of natural marble’s cutting characteristics [5]; it is mainly affected by the machining parameters, which can be optimized by accurate prediction and help increase processing efficiency and save the processing cost. The cutting parameters were optimized when coated tools milling natural marble and an effective analysis on mechanism of milling force was established
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