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浙江大学学报(工学版)
Journal of ZheJiang University (Engineering Science)  2024, Vol. 58 Issue (4): 761-771    DOI: 10.3785/j.issn.1008-973X.2024.04.011
    
Surface roughness modeling of thread workpieces in whirlwind milling considering material deformation
Chao LIU1,2,3(),Zunpeng HUANG1,Shaofu HUANG1,2
1. School of Mechanical and Electrical Engineering, Anhui University of Science and Technology, Huainan 232001, China
2. Institute of Environment-friendly Materials and Occupational Health, Anhui University of Science and Technology, Wuhu 241003, China
3. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030, China
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Abstract  

Surface roughness has an important influence on wear resistance, fatigue strength and contact stiffness of the workpiece. In the process of metal cutting, the surface roughness is greatly affected by the deformation of the workpiece material. An elastic recovery height model for workpiece material deformation was established based on the Hertz elastic contact theory, and a plastic deformation height model for workpiece material deformation was proposed based on the calculation principle of friction and wear. A residual height model of the workpiece surface was established by analyzing the contact motion between the tool and the workpiece. A theoretical model for surface roughness of ball screw whirlwind milling was established based on the influence of workpiece material deformation and residual height. The surface roughness model was validated through whirlwind milling experiments, and results showed that the theoretical model values were in good agreement with the experimental values. The influence of cutting parameters (cutting speed, maximum cutting depth, and number of tools) on surface roughness was analyzed. The relationship between deformation of workpiece materials and surface roughness was revealed.

Key words： surface roughness      material deformation      whirlwind milling      ball screw      plastic deformation      elastic recovery     
Received: 14 April 2023      Published: 27 March 2024
CLC:  TG 501  
Fund:  国家自然科学基金资助项目（52205321，52275228）；安徽省科技重大专项资助项目（202203f07020008）；安徽理工大学环境友好材料与职业健康研究院（芜湖）资助项目（ALW2021YF06）.
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Chao LIU
Zunpeng HUANG
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Cite this article:

Chao LIU,Zunpeng HUANG,Shaofu HUANG. Surface roughness modeling of thread workpieces in whirlwind milling considering material deformation. Journal of ZheJiang University (Engineering Science), 2024, 58(4): 761-771.

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https://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2024.04.011     OR     https://www.zjujournals.com/eng/Y2024/V58/I4/761


考虑材料形变的旋风铣削螺纹工件表面粗糙度建模

表面粗糙度对工件的耐磨性、疲劳强度和接触刚度有重要影响，在金属切削过程中，表面粗糙度受到工件材料形变的影响. 根据赫兹弹性接触理论，建立工件材料形变的弹性回复高度模型. 基于摩擦磨损计算原理，提出工件材料形变的塑性变形高度模型. 分析刀具-工件接触运动，建立工件表面的残留高度模型. 结合工件材料形变和残留高度的影响，建立滚珠丝杠旋风铣削表面粗糙度理论模型. 通过旋风铣削试验验证表面粗糙度模型，结果表明理论模型值与试验值吻合良好. 分析切削参数（切削速度、最大切削深度和刀具个数）对表面粗糙度的影响，揭示工件材料形变与表面粗糙度的关系.


关键词： 表面粗糙度,  材料形变,  旋风铣削,  滚珠丝杠,  塑性变形,  弹性回复 
Fig.1 Deformation area of workpiece material[32]
Fig.2 Deformation of workpiece material[33]
Fig.3 Whirlwind milling process
Fig.4 Contact motion between tool and workpiece
Fig.5 Formation mechanism of residual height
Fig.6 Maximum height of profile
工况v/(m·min?1)Dc/mmNt工况v/(m·min?1)Dc/mmNt
1600.06361400.083
21000.06371400.103
31400.06381400.062
41800.06391400.064
51400.043101400.066
Tab.1 Cutting parameters
参数数值参数数值
几何参数：热膨胀系数/(℃?1)11.9×10?6
轴向节距/mm10.00比热容/(J·kg?1·℃?1)476.975
工件外径/mm62.05Johnson-Cook参数[47]：
齿根圆直径/mm57.95A/MPa2482.4
螺旋角/(°)2.5B/MPa1498.5
热物理参数[46]：C0.027
密度/(g·mm?3)7.81×10?3n0.66
弹性模量/GPa210m0.19
泊松比0.3Tm/℃1 487
导热系数/(W·mm?1·℃?1)4.66×10?2——
Tab.2 Geometrical and physical properties of workpiece
参数数值参数数值
热物理参数[48]：比热容/( J·kg?1·℃?1)750
密度/( g·mm?3)4.28×10?3几何参数：
弹性模量/GPa587前角/(°)0
泊松比0.13后角/(°)9
导热系数/( W·mm?1·℃?1)4.4×10?2刀尖圆弧半径/mm3.3
热膨胀系数/(℃?1)4.7×10?6刀具倒圆半径/mm0.08
Tab.3 Geometrical and physical properties of tool
Fig.7 Experimental verification of surface roughness
μm
工况Ra1Ra2Ra3
10.700 00.708 10.698 2
20.668 70.689 40.664 6
30.598 10.616 00.584 5
40.635 40.605 80.607 6
50.588 40.563 80.569 8
60.684 60.645 70.624 8
70.759 80.731 60.722 6
80.593 40.609 80.579 2
90.598 40.612 70.582 6
100.598 10.607 00.578 5
Tab.4 Surface roughness of workpieces in whirlwind milling experiment
Fig.8 Experimental and theoretical values of surface roughness
Fig.9 Influence of cutting speed on surface roughness
Fig.10 Influence of maximum cutting depth on surface roughness
Fig.11 Influence of number of tools on surface roughness
Fig.12 Variation of plastic deformation height and surface roughness with cutting force
Fig.13 Influence of plastic deformation height on surface roughness
Fig.14 Variation of elastic recovery height and surface roughness with cutting force
Fig.15 Influence of elastic recovery height on surface roughness
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