切削加工のシミュレーション技術

概要

論文の詳細を見る
Recent remarkable advancement of computer performances made possible a metal cutting simulation with finite element analysis. Nowadays, commercial 3D-FEA software specialized in machining processes, such as turning, milling and drilling, is available. This review focuses on a predictability of FEM cutting simulations. Detailed material properties, such as flow stress under high stain rates and high temperatures conditions, friction at tool-chip contact region, thermal conductivity and heat capacity, are indispensable to simulate a metal cutting process in detail. Flow stress characteristics proposed so far, a nonlinear friction property at the tool-chip contact region and equations to estimate tool wear and tool breakage are presented. A prediction of chip controllability with a FEA is shown. Next, a dynamic thermo elasto-plastic FEM cutting simulation is shown. Deformations and temperatures were solved explicitly in the FEA. A penalty force and a correction heat flux that can be adapted to a wide range of cutting condition were considered at the tool-chip contact region in the FEA. Finally, some results of the FEA under ultra high-speed cutting conditions that cutting speed exceeds the plastic wave speeds of a workpiece material are shown as one of examples indicating high predictability of the FEA.