钛合金高速铣削加工的有限元模拟与分析
Finite Element Simulation and Analysis of Titanium Alloy under High-speed Milling

采用有限元法建立了更接近实际的铣刀结构模型及三维铣削模型，模拟了钛合金Ti6Al4V高速铣削切屑的形成过程，得到了铣削过程的温度分布云图，分析了切削过程中残余应力的分布，并提出了采用有限元仿真铣削工件表面的位移大小，把表面的轮廓算数平均偏差作为表面粗糙度评定参数的方法。结果表明：切屑区最高温度出现在距离刀尖0.01~0.03 mm的刀-屑接触处，当主轴转速为9 500 r/min时，温度有所下降。工件的残余应力在表层由拉应力迅速的转变为压应力，在100~200 μm之间出现残余压应力的最大值。当主轴转速为9 500 r/min，每齿进给量为0.02 mm时，表面粗糙度取得最小值。
A three-dimensional finite element model closer to the actual milling cutter structure is established. The chip forming process of high-speed milling titanium alloy Ti6Al4V is simulated, obtaining the distribution cloud atlas of temperature, analyzing the distribution of surface residual stress. A surface roughness evaluation method using the contour arithmetic average deviation as the parameters, though simulating the size of surface displacement of milling workpiece by the finite element, is put forward. The results reveal that the highest temperature in the cutting zone locates on the tool-chip interface at a distance of 0.01~0.03 mm from the tool tip. The cutting temperature decreases when the spindle speed is 9 500 r/min. The tensile residual stress in the surface of the workpiece rapidly transformed into compressive stress,whose magnitude is found at 100~200 μm. The surface roughness obtains the minimum when the spindle speed is 9 500 r/min and the feed per tooth is 0.02 mm