A continuous change of physical and mechanical characteristics and operational properties of functional and structural materials demands a corresponding adjustment of the cutting tool material for machining. The adjustment involves the development of a new tool material and sometimes a new design tool. These two directions of the improvement of metal-cutting tools have a lot of solutions. A look through these options by trial and error is expensive and laborious. Of course, that there are accepted trends in the choice of a rational variant, but they are not justified scientifically and are associated with the experience of the developer. In this situation, it is desirable to simulate the processing of the workpiece with a tool to identify the most preferred solutions for the design and material of the tool. The possibility of using the ANSYS software environment (standard module Workbench Explicit Dynamics) for such a choice of the preferred variants of the design and material of the tool is considered.
The paper reports the concept, the methodology and results of the investigation of possibilities in the application of compound hard-alloy end millers equally with monolithic ones. It is shown that in the majority of operation conditions for general mechanical engineering the compound millers ensure the reduction of tool costs in the cost price of a product at the expense of tool hard alloy saving through manufacturing a miller shank with the use of cheaper material and a place of joining a shank and a cutting element ensures miller operation on high performance modes of cutting without detriment to productivity and machining quality. Material costs at the expense of the reduction of tool hard alloy used are decreased by 30-70% depending on material of a shank and a miller length. The example of compound miller design is presented. The method and results of the deformation computer simulation of such a miller under different operation conditions, error values in machining with a compound miller are illustrated.
The aim was to develop a methodology for monitoring the dynamic state of the links “machine tool – device – cutting tool – detail” comprising a cutting technological system as applied to turning specialized stainless steels using replaceable standard hardmetal inserts. The research object was the hard-to-treat non-corrosive stainless steels 09Х17Н7Ю, 12Х18Н10Т and 13Х15Н5 АМ-3. Monitoring was carried out by simulating plate coatings in the Deform software environment. The diagnostic criterion was the tool life period up to the wear level of 0.5 mm along the rear edge. The effect of coatings on the tool life period was assessed according to the following parameters: temperature in the cutting zone, tension in the tool material and tool deformation. As a result, 10 optimal coatings having the greatest impact on the state of the cutting technological system under study were selected. These coatings can be used for diagnosing the state of cutting technological systems. The coatings were distinguished in terms of architecture (design, composition,structure and coating method). A technique for monitoring and managing the state of cutting technological systems according to the results of diagnostics was proposed. The deviation of the revealed state of the cutting technological system from the desired state was estimated by the life period of tools with different coatings for the same time of their operation. The state of the system under study was considered effective provided that the maximum tool life period due to the use of an optimal coating was achieved. A technique allowing assessment of the state of technological cutting systems by their simulation according to the parameters “temperature in the cutting zone”, “tension in the tool material” and “tool deformation” was proposed. This technique also permits monitoring of the state of cutting systems by the parameter "tool life period" and managing their state according to the results of diagnostics through the use of the most optimal plate coatings. The developed technique can be used to reveal the optimal parameters of the cutting mode of hard-to-treat specialized corrosion-resistant steels.
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