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Plunge milling cutter withstanding greater loads in heavy milling can cause tool breakage, cutting vibration, even chatter. Firstly, geometric model of plunge milling cutter on various combinations of axial rake angle and radial rake angle are established. Secondly, with combination different axial rake angle and radial rake angle of plunge milling cutter under static load, the amount of deformation plunge milling cutter are calculated by finite element analysis. Finally, the plunge milling cutter first six natural frequencies are given in plunge milling cutter modal analysis with finite element analysis. The results show that minimum total deformation of plunge milling cutter is given with the axial rake angle 5° and radial rake angle-5 ° of the cutter and when the tool working at frequencies up to 10012HZ has caused vibration within the XY plane.

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.

In this paper, numerical simulation method is used to study the turning tool strength by Deform 3D in the process of rough machining high strength steel (2.25Cr-1Mo-0.25V).It mainly studies the effect of the feed rate on the cutting force. At the same time, non-uniform distribution cutting force got from the simulation results is taken as the numerical simulation mechanical load of turning tool blade strength to study the influence of feed rate on the turning tool strength. The simulation results show that: with the feed increasing, the mechanical load that turning tool blade bears increases. The maximum effective stress and displacement of the turning tool blade is also increased.

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 (fz) 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 (fz) significantly affects the cutting forces, but slightly influences the maximum temperature of the chip.

Ni-based super-alloy GH4169 that is most widely used in aerospace is one of the most difficult-to-cut materials, which can be machined by Polycrystalline Cubic Boron Nitride (PCBN) tool. In this paper, the cutting process of super-alloy GH4169 with PCBN tool is researched by simulation, combing with the comparison and verification of experiment. The change rules of cutting temperature and force under different cutting parameters are obtained in this study. The reasonable parameter ranges of high efficiency cutting are proposed in cutting parameter optimization, in order to provide a reference for high efficiency machining of super-alloy GH4169 with PCBN tool.

In this paper, the effects of cutting parameters and tool geometry parameters on the damaged layer were investigated with precision cutting of high strength alloy experiments. The mechanical and thermal effects on microstructure of sub-surfaces in precision turning high strength alloy are studied with a scanning electron microscope (SEM) analysis. A thin disturbed or plastically deformed layer is distinguished by the presence of grains that are elongated and rotated in the direction of cutting. No significant heat affected layer and phase transformation is found below the machined surface in all the tests. It also implies that mechanical deformation plays a larger role during precision turning.

In this paper, the effect of cutting parameters on cutting force, cutting temperature and surface roughness on cutting force, cutting temperature and surface roughness are experimentally studied in spray cutting GH4169 Ni-base superalloy used carbide cutting tools. The results showed that reasonable choice of cutting parameters can effective reduction of cutting force and cutting temperature, and improve the machining surface roughness. Thus realizing clean production mode.

Analyzing and researching the main failure forms of the hard alloy turning tool in rough machining process of the hydrogenated cylindrical shell’s blank. Then the cutting experiments were done at the site, and the results showed that the main failure forms of the hard alloy turning tool in rough machining process of the blank were tools’ fracture. However the main reason leading into this phenomenon was the mechanical impact of variable frequency and variable load which was caused by the dynamic change of cutting dosage. Integrating the experiment results, and combining the principles of elasticity and the principles of fracture toughness of hard alloy, the measures of protecting the tools from being fractured prematurely in heavy cutting process were worked out, then the research result would provide reference database for practical production.

During precise hard cutting, back cutting depth and feed rate are relatively small. Study on the influence of PCBN (Polycrystalline Cubic Boron Nitride) cutting tools edge (chamfer edge or cutting edge radius) on cutting force is important. As the effect of cutting edge on mechanism of shear slip plane is very complicated, so to study the effect of consider cutting edge parameters and cutting parameters by genetic algorithm on cutting force, to build up cutting force model of precise hard cutting. It is feasible to predict cutting force by genetic algorithm with experiment.

Firstly, with studying three typical aspects as cutting force, cutting temperature and chip breaking behavior, contrast experiments of machinability were made on hydrogenated cylindrical shell materials (2.25Cr-1Mo-0.25V), 45 steel, and stainless steel (1Cr18Ni9Ti). The experiment results show that the depth of cut ap have a larger effect on the main cutting force FZ and the cutting temperature θ than the affection of the feedrate f, for that reason, in order to reduce the main cutting force FZ and the cutting temperature θ, large feedrate situation will be better for machining work of hydrogenated cylindrical shell materials. When cutting hydrogenated cylindrical shell materials , many difficult points appearance, such as large cutting force, high cutting temperature, serious chips winding, chips difficult to break etc, which has worse machinability even than stainless steel(1Cr18Ni9Ti).

PCBN cutting tools is in high speed, high temperature and high pressure environment when high speed precision hard cutting hardened steel. Shear extrusion and slip effect in high speed cutting, cutting tools wear mechanisms are different from common cutting, even cutting tools wear mechanisms in high speed is in research stage at present. In this paper, coated PCBN cutting tools wear mechanisms in high speed cutting(v＝200~600m/min) GCr15 (HRC62-64) is studied, it is helpful to obtain cutting tools structure design, cutting parameters and improve cutting tools use efficiency.

The generation procedure of saw tooth chip when PCBN tools orthogonal cutting hard steel GCr15 is emulated by FEM software ABAQUS in this study. The model effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation. The effects of cutting edge preparation on cutting force, cutting temperature and residual stress are analyzed. Results of FEM show that cutting edge preparation has a great impact on cutting procedure. Under the same cutting condition, cutting force, temperature and residual stress of sharp edge, honed edge and chamfered edge increases in turn, and three kinds of cutting edge have the same change rule in residual stress. Chamfered edge has a good temperature distributing, and it is the best edge preparation in hard cutting.

PCBN cutting tool’s wear in high speed precision reaches tool wear criterion will cause cutting force and cutting temperature increase clearly, chip color change or melt. Even vibration in cutting will influence dimension accuracy and surface quality of workpiece. It is very useful to establish model by FEM simulation of tool wear predicted. The influence of tool wear in cutting conditions will assurance of machining quality and efficiency, decreasing rate of product cost. PCBN cutting tool’s wear is simulated by FEM software Deform 2D, rake face wear state can be analysed by the influence of tools geometric parameters and cutting parameters tool wear.