① Import the cutter bar and gear blank models established in UG into advancededge software according to the actual machining position (see Figure 1).
Carbide general cemented carbide is selected as the material of the tool, and the minimum mesh size of the tool is set to 0.2mm; The workpiece material aisi-4120, i.e. 20grmnmo alloy structural steel, is selected, its hardness is 248bhn, and the minimum grid size for dividing the workpiece is set to 0.1mm. In the process parameters tab, set the cutting speed as 180m / min, i.e. 325.54r/min. Use the feed motion to replace the tooth splitting motion of the cutter head rotating around the gear blank axis. It is specified that the feed of each tooth is 16mm / T, and use the motion in the other direction of slope milling to replace the feed motion. It is specified that the angle of slope milling is 0.0358 °, and the actual feed speed is 0.01mm/t, Set the total cutting distance to 50 °.
② According to the set parameters, the cutting simulation is carried out in advantageedge software. After about 20h operation calculation, the simulation results are shown in Figure 2.
Figure 3 shows the cutting force and cutting temperature of the tool in the X, y and Z directions during the cutting process. It can be seen that the cutting force in Y direction is the main cutting force, which is the largest when cutting in, and then tends to be stable; The cutting temperature increases with the progress of cutting.
③ By changing the cutting speed, feed speed and slope angle as important parameters in the blade structure, the cutting process is simulated to obtain the cutting force and cutting temperature in each cutting process. The parameters of main cutting force (i.e. Y-direction cutting force) and cutting temperature varying with cutter head angle are derived, the average value of cutting force and the maximum value of cutting temperature in each simulation process are calculated, and the results are compared.
Fig. 4 is the variation curve of main cutting force and cutting temperature with cutting speed. It can be seen that when the cutting speed increases from 150m / min to 210m / min, the main cutting force decreases and the cutting temperature increases.
When the feed rate f increases from 0.01mm/t to 0.02mm/t, the main cutting force increases and the cutting temperature increases slightly (see Fig. 5).
When the inclined angle of the blade increases, the rake angle of the blade increases and the absolute value of the negative edge inclination increases. As can be seen from Fig. 6a, the main cutting force decreases slightly when the inclined surface of the blade increases from 8.5 ° to 12 ° and 15.5 °; As can be seen from Fig. 6B, when the blade slope increases from 8.5 ° to 12 °, the cutting temperature decreases, but when it increases to 15.5 °, the cutting temperature increases slightly.
According to the simulation results, the cutting parameters and the blade slope angle during the cutting test are determined as follows: the cutting speed v = 180m / min, the feed speed f = 0.01mm/t, and the blade slope angle is 12 °.