Papers by Author: Fu Gang Yan

Abstract: Fir tree groove broaching is prone to deformation, which affects the machining precision of rear wheel groove. The numerical broaching force is calculated to improve deformation of the processed round tank .This paper uses the planer to make cutting tests that are carried out in shaping machine to simulate the wheel broaching process and measures the cutting force in the experiment. After analyzing the unit numerical cutting force of GH4698 broaching is finally obtained. It provides a simple method to calculate the cutting force of wheel groove machining.

Abstract: In traditional model of high-speed cutting, each modeling or modify process, material parameters input, boundary conditions set take up a lot of time, the solution process has blindness and not easy to operate. this article uses the python language, based on ABAQUS to secondary development of cutting simulation model in pre-treatment, establish exclusive two-dimensional cutting simulation interface, realization the parametric settings of tool angle, the size of the tool and the workpiece, cutting parameters, parametric design can shorten the time of modeling, and lay the foundation for the establishment of the high efficiency and high accuracy of the simulation model.

Abstract: The three-dimensional finite element modeling and experimental validation of plunge milling of stainless steel (1Cr13) are presented. The commercial software Deform 3D applied for the finite element modeling is studied the effect of feed rate per tooth (f_z) on the cutting forces and the temperature fields. The formation of chip in the finite element model is formed by local adaptive remeshing technique. The feed rate per tooth (f_z) significantly affects the cutting forces, but slightly influences the maximum temperature of the chip.

Abstract: For improving heavy milling machining environment, take the vibration modal and noise radiation distribution of milling cutter-workpiece as the research object, according to the characteristics of milling, consider vibration and noise generation in the milling process comprehensively, first establish the geometry model of cutter-workpiece, and then conduct finite element modal simulation and calculate the vibration response, so as to predict the distribution of noise field, and analyze the noise radiation, finally verify the vibration noise distribution of cutter-workpiece through milling noise distribution experiments, which lays the foundation for further research on vibration and noise reduction in heavy milling process.

Abstract: In the process of cutting, the problem of flying chips seriously affect the processor’s life safety and the processing environment of workshop. In order to study the characteristics of the chips flying, the authors selected five different kinds of commonly used milling insert, and use these milling insert in the dry milling experiments to study the process of cutting chips flying. In the paper, firstly, carried out flying track analysis on the chips, and concluded the chips flying theory, and then design the cutting experiment, through the statistical analysis of experiments data, to understand the influence of different insert groove chip and cutting parameters to chip flying, and puts forward suggestions on groove development of heavy-duty cutting inserts.

Abstract: Ball-end milling cutter is widely used in machining complex surface parts , and it is need to select a reasonable geometric parameters of the milling cutter for different work piece materials and shapes and cutting parameters. This article is based on UG secondary development technology to develop the Multi-blade ball-end milling cutter parametric design system, it is automatic, fast and efficient to build all kinds of parameters of double, three and four blades ball-end milling cutter model required for user.

Abstract: In cavity die corner-machining, tool flexible deformation caused by the milling force resulting in the surface error, a method of off-line error compensation is put forward. Instantaneous chip thickness model and the corner milling force model is established based on differential and the characteristics of the corner. Combining the theory of cantilever beam and the finite element analysis, cutting tool elastic deformation model is established.

Abstract: In heavy-duty cutting, large chips produced are wide, thick and of complex shapes. If the large chips are not controlled reasonably they will heavily influence the machining efficiency. This article researches on the generation process of large chips, and is combined with the research method of finite element simulation to establish curling model of large chips in heavy-duty cutting process. Through analyzing the fracture strain and cut strain suffered by the chips in the curling process of large chips and enlarging the large chips using electron microscopy, the generation and curling deformation law is revealed. And analyzing generation and curling mechanism of large chips can provide theoretical basis for the generation and control of ideal chips in heavy-duty cutting process.

Abstract: In the machining process of large parts, the dynamic alternating loading suffered by heavy carbide insert is very large, so the fatigue failure of the insert is serious. Through the analysis the effect of dynamic alternating force - thermal load on insert’s crack, and the fatigue crack experiment of inserts under dynamic alternating loading will be done, the formation conditions and distribution law of fatigue cracks can be researched under the effect of dynamic mechanical shock and thermal shock. And the fatigue crack will be theoretical analysis through the fatigue curve in the range of test cutting parameters. It can provide effective basis for the optimizing the heavy-duty cutting parameters and reducing the fatigue crack failure of heavy-duty cutting insert.

Abstract: In this paper, the machinability of surface is introduced, and it is obtained from the analysis that the main macroscopic factors of tool premature failure are forging defects. Through research on the mechanism and rule of heavy-duty turning tool fracture failure, the conclusion is obtained that dynamic load leads to tool fracture and breakage finally. The tool working state under dynamic load is analyzed similarly by finite element software, and the simulate result verifies accuracy of the conclusion. Finally, the critical time model of tool fracture under dynamic load is established and the prevention measures of tool premature failure are formulated, which provide reference for the improvement of production efficiency and tool breakage prediction.