Development prospect of Cutting simulation technology in China

Keywords: cutting, simulation technology, tool |technical information | source: Chinese journal of mechanical engineering

Cutting simulation technology plays a vital role in university teaching, scientific research, production and r&d of enterprises, but it has not been paid attention to by the industry before because of its interdisciplinary nature, high threshold and low efficiency, and lack of intercommunication between schools and enterprises.Nearly three...

Cutting simulation technology is of vital importance to university teaching, scientific research or enterprise production, research and development. However, because this technology belongs to an interdisciplinary subject, the threshold of learning is high, low efficiency, coupled with the lack of school-enterprise communication, so it has not been the attention of the industry before.In the past three years, with the rapid development of China's manufacturing industry, as well as the rise of domestic cutting simulation innovation team and the holding of the international conference on cutting simulation, more and more professionals began to realize the importance of this technology, especially tool and aerospace enterprises.Then, the cutting simulation of this sunrise technology in the end what specific content, how to configure the school and enterprise resources to accelerate its industrialization process, and in the next three years in China's cutting simulation technology can have what kind of development?Now let's elaborate on this.

Improve the cutting simulation base process case

Although there have been relevant literatures on cutting simulation technology in Chinese universities for a long time, most of them are based on research and development needs rather than enterprise needs. At the same time, due to the alternation between old and new graduate students in universities, this technology has not formed systematic simulation theory and technology accumulation.Therefore, it will promote the continuous development and industrial application of cutting simulation technology in Our country if we can build a school-enterprise common cutting simulation base.

The specific contents of the case base are as follows:

1) Indentation simulation and scratch simulation

Indentation and scratch simulation is a common simulation method for researchers engaged in the topic of cutting direction. This method can reveal the mechanism of material removal, analyze the surface morphology of scratches, and optimize the process parameters of scratches.

2) Simulation of turning, milling and drilling

There are three common processing methods for cutting, namely turning, milling and drilling. However, due to the difficulty and low efficiency of 3D cutting simulation, the research on 3D turning, milling and drilling simulation in domestic and foreign literatures has not been popularized and applied.

3) Ultrasonic vibration cutting simulation

Ultrasonic vibration machining is a typical auxiliary machining mode, so the simulation research in this direction has certain guiding significance for exploring ultrasonic removal mechanism, optimizing ultrasonic process parameters, and developing ultrasonic equipment.Especially when the coupling relationship between ultrasonic parameters and cutting technological parameters is studied, a large number of experiments will inevitably increase the cost of research and development. At the same time, if the cutting quality under extreme conditions, such as amplitude and frequency, is studied by carrying out experiments, the efficiency of scientific research will be reduced or the risk of scientific research will be increased to some extent.

4) Tool texture optimization simulation

Through increase in tool surface texture method for optimization of its wear resistance is an effective method, however, texture type, size and spacing factor has too many kinds of combination and evolution, if all carried out by using the method of experimental research will greatly increase the cost of scientific research, as a result, the optimized simulation of the cutting tool texture can partly replace related scientific research experiments.

5) Molecular dynamics cutting simulation

It is necessary to use molecular dynamics method and software to study the nanoscale processing mechanism of monocrystalline silicon and copper.The core of the analytical dynamic cutting simulation method is to use potential function to calculate the atomic force between the tool and the tool, and then analyze the atomic image, energy and cutting force during the cutting process.

Break through the core technology bottleneck of cutting simulation

At present, there are a lot of documents, videos and source files related to cutting simulation, both in reference and grid data, but most of these are written by graduate students in universities. The content is not comprehensive, the knowledge is not systematic, and the interface operation is emphasized while the basic theory is ignored.Although it can be used as a reference for beginners, but a long time will find their own technology always stay at a primary level, it is difficult to have a qualitative leap.Therefore, in order to carry out deep learning and combine simulation technology closely with scientific research and industry, the bottleneck of related core technology must be broken.

So in terms of the current cutting simulation technology, what are the bottlenecks that need to be broken, and what can we do within three years?Now let's give you a detailed explanation:

Cutting simulation core technology bottleneck:

1) Simulation efficiency is improved

Cutting process simulation is a typical nonlinear analysis, specific include: the material nonlinearity, geometric nonlinearity and nonlinear contact, at the same time because of up to millions of 3 d knife model grid, so the relative structure analysis for the efficiency of cutting simulation is very low, if want to consider the temperature of cutting simulation that will need to be calculated using the workstation.

2) Residual stress simulation

The residual stress simulation needs to consider both the display calculation and the implicit springback analysis, and maintain the same material constitutions in the two analysis processes. The difficulty is to pick up and remove the failure elements after the display calculation before the implicit springback, so as to ensure that there is no rigid body displacement during the springback.

3) Tool wear simulation

In order to simulate tool wear, two conditions are required: first, the determination of tool wear constitutive;Secondly, the tool wear parameters are obtained.As far as the wear constitutions are concerned, there are currently only two, the Archard constitutive and the Usui constitutive, both of which can only be used for implicit analysis, the difference being that the former cannot take temperature into account while the latter can.Therefore, in order to carry out cutting simulation tool wear analysis, it is necessary to carry out display and implicit conversion and carry out a large number of repeated cutting simulation iterations to obtain the new tool profile, Angle and friction coefficient and other parameters after wear, so the efficiency is relatively low.

4) Coolant simulation

The coolant has three functions: cooling, lubrication and rust removal.It is difficult to simulate three functions simultaneously in the process of cutting simulation.As far as the current simulation technology is concerned, only cooling and lubricating effects can be achieved.The cooling effect of the coolant can be achieved by convective heat transfer coefficient, and the lubrication effect can be achieved by changing the friction coefficient of the tool.

5) Deformation prediction of thin-walled parts

After a lot of research, most aviation and aerospace enterprises focus on thin-walled parts cutting. For thin-walled parts cutting simulation, deformation and residual stress of the workpiece are the main application scenes, so the displacement, plastic strain and residual stress of the simulation output unit should be used as evaluation criteria.At the same time, due to the high precision and small cutting margin of thin-walled parts, the mesh size will be relatively small, and the simulation efficiency will be correspondingly low.

6) Composite cutting simulation

Now, mainly for metal matrix composites cutting simulation particle composites and carbon fiber composite materials, mainly for the former is given priority to with micro cell body simulation, mainly for fiber composites material constitutive and parameterized modeling plug-in development, the pilot work has been completed technology accumulation and has formed the relevant software copyright and patent and other intellectual property rights.

3. Establish the evaluation system of cutting simulation system

Whether universities or enterprises, whether teachers and students or engineers are very concerned about a core problem, that is, cutting simulation is good or not.Therefore, in order to allow the technology to be recognized by professionals and be applied and promoted in the industry, it is necessary to establish a macro evaluation system for schools and enterprises as well as related industries, and on this basis to improve and expand, and then form the industry standard of cutting simulation.Generally speaking, the evaluation system mainly includes the following three parts: simulation quality evaluation, university scientific research evaluation and enterprise r & D evaluation.

Basic components of the cutting simulation evaluation system:

1) Determination of evaluation indicators

2) Selection of process standards

3) Optimization of control standards

4) Improvement of simulation efficiency

5) Improvement of standard methods

6) Evaluation of the establishment of the program

4. Hot spot analysis of Chinese school-enterprise cutting simulation technology demand

Although universities and enterprises will use cutting simulation technology, but because of the different evaluation mechanism, researchers in universities and technical personnel in enterprises have a certain difference in the demand for this technology.For colleges and universities, because it is a scientific research institution and are mostly evaluation mechanism research papers, engaged in the study of traditional cutting cannot be a high level of scientific research papers published, although has just issued by the ministry of science and the about breaking the evaluation of science and technology "paper" only bad oriented measures (try out) "notice, but doesn't mean you can't high level scientific research papers published, at the same time on the specification using SCI papers relevant indicators of institutions of higher learning to establish correct evaluation of several opinions of the subjects for technology research and development classes also explicitly pointed out should pay attention to evaluation in the achievements and support the performance of the industry development, etc.So the university scientific research personnel to research papers and achievements transformation effect can give attention to two or morethings, from the perspective of the special cutting simulation, such as: laser assisted cutting simulation and cutting simulation, ultrasonic vibration aided edm machining simulation, at the same time can also click the following link understanding based on the concept of industrialization of science and technology thesis innovation model and evaluation standard.Enterprises take production as the main goal, and the evaluation mechanism is efficiency, quality and cost. Currently, there are two kinds of enterprises that can be used for cutting simulation, one is aerospace enterprises, the other is tool enterprises.Through investigation and visit, we found that the former has an urgent need for thin-walled parts deformation and residual stress simulation in the process of turning and milling, while the latter also has a potential demand for traditional cutting simulation such as structure and material optimization of various non-standard cutting tools.

Demand point analysis of school-Enterprise Cutting simulation:

1) University requirements: laser-assisted cutting simulation, welding cutting simulation, metallographic cutting simulation

2) Enterprise requirements: heat treatment cutting simulation, tool magnetization cutting simulation, tool cryogenic cutting simulation

3) Common requirements: Tool wear, residual stress and coolant in traditional cutting simulation

A strong guarantee for the sustainable development of cutting simulation technology

Sustainable development is the specific connotation of green development in intelligent manufacturing. In terms of cutting simulation technology, the core of its sustainable development is to form a virtuous circle among necessary elements of cutting simulation, such as database, high-end person-time, school-enterprise resources, etc., so as to realize the deep integration of data improvement, talent training, and production and education information.So to really play a cutting simulation technology in scientific research in colleges and universities and the role of enterprise development, at the same time constant air and cutting tool in our country enterprise produce benefit of virtual manufacturing, the library must set about building material parameters, knife work model library, high-end talent and industry demand for library information system platform, such as cutting simulation to lead the material cutting simulation technology and boost the development of Chinese manufacturing digital.Among them, the guarantee factors for the sustainable development of cutting simulation technology mainly include:

1) Basic database

2) High-end talent pool

3) Teaching resource library

4) Production and education integration system

5) Support from the national industry and education integration policy

The conception of building cutting simulation system platform

Universities and enterprises have their own requirements for cutting simulation technology. However, there is no cutting simulation software independently developed in China at present, and foreign software is expensive and blocked to China. Meanwhile, the cutting simulation level of everyone needs to be improved.Therefore, if we can start from the demand of school and enterprise, integrate the tool model and material parameters and other resource database, and take traditional and special processing technology as the carrier, the construction of cutting simulation system platform will have certain guiding significance for the research and development and application of cutting simulation technology in Our country.

The main contents of China cutting simulation system platform include:

1) Parametric modeling system

2) Material parameter library

3) Tool model library

4) Simulation resource library

5) Simulation of supercomputing system

The idea of developing domestic cutting simulation software

Cutting simulation system platform to a certain extent, can meet the development needs of college and enterprise, but because of the platform is based on the existing general commercial software as a solver for the simulation calculation, so if you want to have a completely independent intellectual property rights, must be developed for the display of cutting simulation working condition of dynamic solver, development of domestic cutting simulation software to lay the foundation for the next step.Through multiple communication with university-industry researchers, taking enterprise problems as the carrier and university scientific research as the goal, it is preliminarily determined that the future home-made cutting simulation software consists of the following three modules:

1) Remove the mechanism simulation module

The module including indentation, scratch and two-dimensional cutting simulation function, as well as the pressure head and pyramid top of cone parameterized modeling tool, on the basis of output can also be cutting force, cutting temperature and physical quantities such as chip morphology revealed through the removal mechanism of all kinds of refractory materials, provide theory support for the process optimization in the process of machining.

2) Traditional cutting simulation module

The module includes traditional cutting simulation processes such as turning, milling and drilling, as well as a large number of tool models such as turning tool, milling tool and drill bit, through which simulation support can be provided for tool material optimization, structure optimization and workpiece residual stress and deformation prediction in traditional cutting process.

3) Special machining simulation module

The module is in the literature at home and abroad were reviewed and fully research at the same time, with the domestic aviation enterprise r&d staff communication on the basis of the development of many times, by means of electricity, heat and mechanical energy and the processing simulation method of remove or add material, including laser assisted cutting simulation and cutting simulation of materials after heat treatment and welding material cutting simulation, and other functions.
 

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