134
Q.-Q. Cai et al.
[7, 8]. During the cutting process, the microstructure of the superalloy material has
high hardness, high shear stress, and low thermal conductivity, which is easy to cause
problems such as high cutting force and high cutting temperature. It also has difficulties in chip breaking and serious wear and tear of the tool [9, 10]. Therefore, it is easy
to affect the quality of the processed surface of the workpiece and reduce its service
life. Therefore, it is necessary to quickly solve the problem of poor performance
during the cutting process of superalloys [11, 12].
Based on the bionic tribology theory, texture processing on the tool surface can
effectively improve the wear resistance of the tool [13, 14]. Research in the past few
decades has confirmed that the placement of micro-texture on the tool surface has
a positive effect on improving the friction contact state of the tool-chip interface,
anti-adhesion, wear resistance and drag reduction, and storage of chips [15–17].
In this paper, the ABAQUS6.14–1 software is used to carry out the micro-array
array orthogonal micro-cutting superalloy simulation test research [18–20]. The solid
modeling of the tool and the workpiece were carried out respectively, the micro-pit
arrays with different diameters were prepared on the surface of the micro turning
tool, and the tool-chip contact state, chip stress distribution, cutting force, cutting
temperature and chip shape were analyzed during the cutting process [21–23].
11.2 Creation of Finite Element Model
Solid modeling of the tool and the workpiece respectively, tool side length s =
6.35 mm, tool thickness d = 2.38 mm, tool rake angle γ = 0°, back angle α = 7°,
blade inclination angle λ = 0°, the tip angle θ = 80°, the blade radius r = 0.002 mm,
the tip radius is R = 0.1 mm; Work piece length L = 10 mm, width k = 10 mm. In
order to be able to accurately carry out simulation experiments, local optimization of
the model: tool side length L = 0.280 mm, width d = 0.150 mm, micro-pit diameter
is 0.035 mm, 0.030 mm, 0.025 mm, 0.020 mm, depth is 0.01 mm, 6 × 10 micro-pit
array, pit center distance is 0.06 mm; workpiece length L f = 0.600 mm, width k f =
0.080 mm, cutting depth a p = 0.01 mm, cutting speed v = 400 mm/s, as shown in
Fig. 11.1.
The cutting tool material is cemented carbide (92 wt. % WC, 8 wt. % Co).
The detailed parameters of physical and mechanical properties are shown in Table
11.1. The workpiece material is superalloy GH4169. The chemical composition and
physical mechanical properties of the superalloy are shown in Tables 11.2 and 11.3.
11.3 Analysis and Processing of Simulation Results
After the simulation model is constructed, the calculation is submitted, and the calculation results are post-processed in the ABAQUS6.14–1 Visualization module to
output related graphic data.
Q.-Q. Cai et al.
[7, 8]. During the cutting process, the microstructure of the superalloy material has
high hardness, high shear stress, and low thermal conductivity, which is easy to cause
problems such as high cutting force and high cutting temperature. It also has difficulties in chip breaking and serious wear and tear of the tool [9, 10]. Therefore, it is easy
to affect the quality of the processed surface of the workpiece and reduce its service
life. Therefore, it is necessary to quickly solve the problem of poor performance
during the cutting process of superalloys [11, 12].
Based on the bionic tribology theory, texture processing on the tool surface can
effectively improve the wear resistance of the tool [13, 14]. Research in the past few
decades has confirmed that the placement of micro-texture on the tool surface has
a positive effect on improving the friction contact state of the tool-chip interface,
anti-adhesion, wear resistance and drag reduction, and storage of chips [15–17].
In this paper, the ABAQUS6.14–1 software is used to carry out the micro-array
array orthogonal micro-cutting superalloy simulation test research [18–20]. The solid
modeling of the tool and the workpiece were carried out respectively, the micro-pit
arrays with different diameters were prepared on the surface of the micro turning
tool, and the tool-chip contact state, chip stress distribution, cutting force, cutting
temperature and chip shape were analyzed during the cutting process [21–23].
11.2 Creation of Finite Element Model
Solid modeling of the tool and the workpiece respectively, tool side length s =
6.35 mm, tool thickness d = 2.38 mm, tool rake angle γ = 0°, back angle α = 7°,
blade inclination angle λ = 0°, the tip angle θ = 80°, the blade radius r = 0.002 mm,
the tip radius is R = 0.1 mm; Work piece length L = 10 mm, width k = 10 mm. In
order to be able to accurately carry out simulation experiments, local optimization of
the model: tool side length L = 0.280 mm, width d = 0.150 mm, micro-pit diameter
is 0.035 mm, 0.030 mm, 0.025 mm, 0.020 mm, depth is 0.01 mm, 6 × 10 micro-pit
array, pit center distance is 0.06 mm; workpiece length L f = 0.600 mm, width k f =
0.080 mm, cutting depth a p = 0.01 mm, cutting speed v = 400 mm/s, as shown in
Fig. 11.1.
The cutting tool material is cemented carbide (92 wt. % WC, 8 wt. % Co).
The detailed parameters of physical and mechanical properties are shown in Table
11.1. The workpiece material is superalloy GH4169. The chemical composition and
physical mechanical properties of the superalloy are shown in Tables 11.2 and 11.3.
11.3 Analysis and Processing of Simulation Results
After the simulation model is constructed, the calculation is submitted, and the calculation results are post-processed in the ABAQUS6.14–1 Visualization module to
output related graphic data.