Turning force in turning process of gray cast iron material for engine cylinder block

In recent years, many studies have been carried out on the evaluation of cutting performance of materials by cutting force combined with other parameters. However, these articles only explain the cutting parameters in the cutting process. There is no mention of whether the engine block is cut with gray cast iron, whether only one tool is used to cut different materials, and whether the turning tool is installed at one time to complete the cutting force comparison of gray cast iron for engine block. If a tool is installed at one time to complete the comparison of cutting forces of different materials, the change of cutting force caused by tool wear is not considered in the paper; If the tool change and tool reassembly are carried out in the cutting process, the change of cutting force caused by tool change and tool reassembly is not considered. When people use the cutting force to evaluate the machining performance of materials, the actual situation is that they often change the turning tool constantly during cutting because they are afraid of the impact of tool wear on the cutting force. Even if the parameters of the tool are completely consistent, the small deviation of the tool installation position during the tool change process will also cause the change of the cutting force of gray cast iron for the engine cylinder block. This difference in cutting force caused by tool replacement will affect the evaluation of cutting force of different materials. The change of cutting force caused by tool replacement will even exceed the change of cutting force caused by different materials, resulting in the inability to accurately evaluate the machining performance of materials. This situation is often ignored.

Taking a homogeneous material as the cutting object, it is verified that the tool wear can be ignored under the same cutting parameters, and the effects of blade reassembly and integral clamp tool reassembly on the main cutting force of gray cast iron for engine cylinder block are investigated.

The stress-strain system is calibrated by the mounting method, and the turning force measurement in the process of material turning is analyzed and studied through the gray cast iron stress-strain system for engine cylinder block combined with tool wear. The main results are as follows:

1.The three-way force mounting calibration device can calibrate the gray cast iron stress-strain system for engine cylinder block simply, quickly and accurately during the measurement of turning force. The calibration device is easy to use, directly uses the standard weight as the reference, and can realize the accurate force application in three mutually perpendicular directions.

2.Under the condition that the tool wear is negligible, examine the impact of the blade reassembly of the opposite tool and the clamping tool and the overall clamping tool reassembly on the main cutting force, so as to provide guidance for the evaluation of the cutting force of different materials. For the clamping tool, the change of cutting force caused by blade reassembly and replacement is small, but the reassembly of the overall tool causes a large change of cutting force. Therefore, when using the cutting force of gray cast iron for engine cylinder block to evaluate the machining performance of materials, if the machining performance of materials is not very different, the change of cutting force caused by tool replacement may be greater than the difference of real cutting force of materials, so it is impossible to evaluate the cutting force of materials. When using integral tools, even if the same batch of tools, their shape parameters will not be exactly the same, which will cause greater changes in cutting force. When evaluating the machinability of materials with the cutting force of gray cast iron for engine cylinder block, the machine clamp tool is used, and the blade can be replaced, but the cutter rod needs to be installed at one time.

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