Numerical simulation of the influence of cutting parameters on the cutting process of ZrO2 ceramics
Objectives:Research on ceramic processing primarily focuses on areas such as single abrasive grinding methods,processing mechanisms,processing efficiency,material removal mechanisms,and surface quality.However,research on ZrO2 ceramic cutting processing is relatively insufficient.Therefore,the 3D cutting process of ZrO2 ceramic workpieces was numerically simulated using the finite element simulation method.The study discusses the mechanism of chip removal,the dynamic change and distribution of stress,and the evolution law of cutting force under various cut-ting conditions.Methods:The 3D cutting process of ZrO2 ceramic workpieces,under different machining parameters and tool parameters,was numerically simulated using the finite element simulation method.The cutting forces under various feed speeds and cutting depths were compared to explore the failure modes and material removal mechanisms of ZrO2 ceramic during the cutting process.Results:The hard contact behavior between the cutting tool and the workpiece significantly affects the material removal process,leading to failure modes such as chip collapse,material cracking,and crack propagation.When the cutting depth is 200 μm or 250 μm,numerous cracks appear at the end edge of the work-piece and expand in the vertical cutting direction,resulting in significant fragmentation at the edge.An increase in cut-ting speed will causes fluctuations in stress and cutting force,but overall,there is no significant change in cutting per-formance.The radius of the cutting edge affects the formation of cracks in the initial cutting stage.As the edge radius in-creases,the length of the crack at the front end of the tool shortens,though the impact on cutting force is not significant.A negative tool rake angle during cutting does not induce cracks in the workpiece,and it leads to better machining qual-ity.In addition,when the tool rake angle is 0 °,the maximum cutting force increases rapidly,but the cutting force vari-ation is not obvious with increasing rake angle.Conclusions:As the cutting depth increases,the stress layer on the tool surface gradually expands from the tip to the front and rear cutting surfaces,and gradually increases.As the cutting depth increases,local cracks form at the cutting end of the workpiece and propagate downward.The position of maxim-um stress on the front cutting surface of the tool gradually increases with the increase in edge radius.However,the influ-ence of the edge radius on the cutting force is relatively small.When cutting ZrO2 ceramics with a tool featuring a negat-ive rake angle,no internal cracks are caused,and good machining quality can be achieved.
ZrO2 ceramicsfinite element simulationcutting depthcutting edge radiustool rake anglecutting speed
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