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.10

1.2.1.1

..11

1.2.1.2

13

1.2.1.3

15

1.2.2

........................................................17

1.2.2.1

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1.2.2.2

...18

1.3

18

1.4

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- ..22

1.5

, .25

1.5.1

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1.5.2

25

1.5.3

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1.5.4

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1.6

( ) ..28

1.6.1

28

1.6.2

29

1.6.3

s = ..29

1.6.4

r ...30

1.6.5

r = 30

1.6.6

.31

1.6.7

.32

1.6.8

..32

1.6.9

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2 - .35

2.1

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40

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2.4.3

43

2.5

.45

3 - 47

3.1

.47

3.2

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3.2.2

51

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3.2.4

53

3.2.5

54

3.2.6

55

4 - .. ..58

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4.1.1

67

4.2

- (
).......72

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5

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90

 1
1.1

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, t1: .

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.

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, A1 = bxt1.

, A2 = bxt2. [3]

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, a:
mm.

, :
m/min.

, s:
. mm/rev mm/
.

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.
m/min .

, :
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.
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.[3]

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10

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14

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15

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16

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17

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1.2.2.2

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18

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19

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20


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21

 1.9 , .
SAE 1095, = 66 m/min, t = 0,195 mm, = 100
0C.

1.4

1.4.1 .

,
, 1200 0C,
106 0C/s. ,

,

/,
/. ,



.
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22


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23

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24

1.5

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, (f x a x v t1 x b1 x v)
, .

Taylor :

Tvl/nfl/mal/k = C1 n, m, k, C1 .
,
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l/>l/m>l/k.

1.5.2

,
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25

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140 3,50 .


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80

60 .

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26

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0,50 0,70 .

1.5.4 .

. ,
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.

1.5.5 .

27

1.6

( ) .

, ,
: , , s,
r, r ,
, ( ),
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.

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, ,
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28

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FH.
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.

1.6.2

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1.6.3

s = .

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.
s = -50 +50, ,
FH ,
FV ( ) FA ( ),
.
s
,
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.

29

 1.11 ) , )
.

1.6.4

r .

.
,
. ,
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a. FA r,
FV.
FR
r.

1.6.5

r = K .

,
. , h

30

 ks,
.
FH, FA FV
1.12.
FA FV FH.

2.12.
FH, FA FV.

1.6.6

. ,
.

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31

 ,
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1.6.7
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FH,
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1.6.8 .

a FH, FA FV
,

s. , ,
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s.
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(A=f x a). ,
FH .

32

 , a, b1
, ( ) .
, a
.

1.6.9 .

FH,
.
FH
, ,
1.13..

.
, , ,
( , , ..
), FH ,
[2.2.1].
FH . FH
,
.
, ,
,
. , ,
40 m/min, ,
.
FH.

33

 2.13 FH
.
)

FT ,

.
)

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).
)

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)

34

2.1 .

, (. 2.1)
,
.
.
(
). (Al2O3),
, , .[1]

,
, ,
. .
,
. .

. 2.1. .

35

2.2 .

Al,
, 660,37C, 2467C
2.7g/cm.
2,5-6,3% .. .
,
. ,


-.
,
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.[2]

2.3 .

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.

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.[1]
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36

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(.1).

1. .

12%,
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.

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6%, .
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, .

(Aluminium Association)
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4
(temper designation).[2]

2. .


(Al)
(Cu)
(Mn)
(Si)
(Mg)
(Mg2Si)
(Zn)

1
2
3
4
5
6
7
8
9

(Al)
(Cu)
(Si-Cu-Mg)
(Si)
(Mg)

(Zn)
(Sn)

37

1.
2.
3.
4.
5.
6.
7.
8.
9.

 1000, 3000 5000

. , 2000, 6000
7000 . , ,
.
()
1000: 99% Al.
.

. (, , .),
( .) .
Fe Si
0.14% Cu .
3000 (Al - Mn):
Al6Mn (Mn) < 15%.
Mg 1.2%
.
Al+Mn ,
.
5000 (Al Mg):
(Mg) < 4.0%. 5000
Mg .
,
.
Fe Si .
1000, 3000, 5000,
, .
2000, 6000, 7000 .
2000 (Al-Cu): Al Al-Cu
2000 , 2.66.3%
0.51.5%.
CuAl2 / CuMgAl2
. 2024

38

 . 2000
.
6000 (Al Mg Si):

Mg2Si. Mn (< 0.8%) Cr (<0.3%) .
6000 ,

.
7000:
,
. Al Zn Mg Al
Zn Mg Cu (Zn)=48%, (n)=13% (Cu)=<2%.
MgZn2.
(>120C).
()


(shrinkage) (hot cracking) .
Al
.

. 2

. :
(sand casting) S.
.
(permanent mold casting) P.

.
(die casting) D.
,

39

 ,
.
,
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.[1]

2.4 .

2.4.1

.
,
. ,

. .[3]

,
.

40

.2.2. .

.2.3. .

41

2.4.2

(point angle),

(/2)
.

(helix angle),

D
,
h

= arctan

: h .
,

:
( 2r / D ) tan

sin ( / 2 )

= arctan

r: .

:
i. 35 - 40 : (Cu, Zn, Al, ).
ii. 20 30: (, ,
).
iii. 10 13 : .

. : 6 8 .

(chisel angle),
42

=55 , ,

.

2.4.3

( (-C)) (
(-)) , .2.4.
,
.

.2.4. .

43

) :

Dn

(m/min)

1000

) :

(mm/rev)

) :

sz =

s
z

(mm/)

) :

= sn

(mm/min)

) :

a=

D'
2

(mm)

: .
1.

2.

44


1.

2.

: D, mm,
n, rev/min,
z,
d, mm .

2.5 .

,
, .[15]
,
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,
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45

H
. ,
.

.
.

.
, (.3-5)
. [4]

3. ( : ).

(mm/.)
D mm.
2-10
10-20
20-40
40-60

Al

0,05-0,24

0,24-0,3

0,3-0,45

0,45-0,56

4. ( : ).

Al

s (mm/.)
D mm.
2-10
10-20
20-40
40-60
0,06-0,1
0,1-0,18
0,18-0,25 0,25-0,32

5. .

Al

(m/min)

160
230-300

46

3.1

.
,
, ..
,

.

.
( ,
) .

, .
.

,
.

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,
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().

47

 . /
.
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/.
,
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), (,
.)
.
.
solver
.

,
: Lagrange Euler. Lagrange

. Euler
. ,
Lagrange (
Euler,
),
.[5]

.3.1.
Lagrange () ALE ()
48

 -
,
.
Arbitrary Lagrangian-Eulerian, ,
.
.
Lanrange
,

(
), . , , Langrange

(re-meshing)
(smoothening).

(refinement)
.

.
Coulomb F= , F
,

.
, .

,
- . , ,
,
, ,
.
:

49

3.2

AdvantEdge.

3.2.1

AdvantEdge
Third Wave Systems ,
.
Lagrange
: ,
.
,
, ,
.

.
,
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50

3.2.2

, ,
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,

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3.2. .

3.2.3

, .
,
51

 ISO. , ,
CAD
.
.
TiC, TiN, TiAlN Al2O3.
,
(Minimum Element Size),
,

(Maximum Element Size),

.

(mesh grading),
. 0.1 1. 0.1
,
, 1
.
,
(Curvature-Safety controls) 0.2
5, 0.2
, .
,
Segments per Edge 0.2
5.
,
, ,

.

52

 3.3. .

3.2.4

,
, (
),
(, , ).


.
(mesh grading),

. 0.1 1. 0.1
,
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. , 0.5 .
, (curvature-safety) ,
0.2

53

 5, 2.
.
,
(.3.4). f (mm/rev),
v (rpm) a (mm).

3.4. .

3.2.5 .

,
.
(Rapid mode) (Standard
mode) (.3.5). ,
, ,
.
.

54

3.5. .

3.2.6

(solver) Tecplot,
AdvantEdge
, (post-processing).

(.tec) (.twb).
Tecplot (.3.6):
.
,
.

Force Filter (Tool-AdvantEdge Quick
Analysis-Display Options).

55

 Tecplot AdvantEdge Quick Analysis,

Tools, ,
.

3.6. Tecplot.

tecplot
, :

(C|F).

(W/mm).

(s).

Von Mises (MPa|Psi).

)(MPa|Psi).

(MPa|Psi).

: XX, YY, ZZ, XY, XZ, YZ (MPa|Psi).

, , (m/min|ft/min).

56

 video
(ToolsAnimateZones), ,
.
AE Data Set
Analysis
(.3.7), ..
.

3.7.
.

57

 4
4.1

. ,

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AdvantEdge.

.

,
.
, ,
360
1080 .
,

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.
( 40%)
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1080.

.

58


360. , ,
, .

360
=2750rpm
f=0.05mm/rev
136, 30
d=6mm

59

60

 360
=2750rpm
f=0.10mm/rev
136, 30
d=6mm

61

62

63

 360
=2750rpm
f=0.15mm/rev
136, 30
d=6mm

64

65

66

4.1.1 .

( ), , ,
.
6. ( )
.
f (mm/rev)
Fz ()
Fz ()

0.05

180

285

0.10

250

485

0.15

420

658

7. .
f (mm/rev)
(N-m)
(C)

0.05

0.045

75

0.10

0.085

95.5

0.15

0.17

100

8. .
f
(mm/rev)
0.05

0.10

0.15

67


, Redouane Zitoune, Vijayan
Krishnaraj,..[11]. CNC
10kw LATECIS (Toulouse, France) 1a.
Kistler, 1b.
Kistler 5019.

.

68

 1. () (CNC), (b) , (c)

.
: K20 (Grade K20), 6mm,

136 , 30

: Al 2024 ( Al 93.5%, Si 0.5%, Cu 3.8-4.9%,Mg 1.2-1.8%, 0.1% Cr,

3mm.
( rpm) : n1=1050, n2= 2020 n3= 2750.
(mm/rev) : f1= 0.05, f2=0.10 f3=0.15.
69

o (.9-10)
F(N)
.
9
f
(mm/rev)

0.05

2750

Fz
(N)
285

0.10

2750

485

0.15

2750

658

(rpm)

10.
f
(mm/rev)

(rpm)

0,15

1050

Fz
(N)
684

0,15

2020

670

0,15

2750

658

( 2)
a) f=0.05 mm/rev, b) f=0.1 mm/rev, c) f=0.15
mm/rev. 2750 rpm.

70

 2. (a) f=0.05 mm/rev, (b) f=0.1 mm/rev, (c)

f=0.15 mm/rev.

71

4.2 (
).

4.2.1 .

AdvantEdge
(.4.1).

700
600

Fz(N)

500
400
300
200

Fz(N)

100
0
1

4.1.

Fz.

:
(360)
Fz .
f=0.05mm/rev, N=2750rpm Fz Fz=285N
Fz=180N,
37%
. f=0.1mm/rev, N=2750rpm,
Fz=485N Fz=250N
72

 48,4%. , 3 f=0.15mm/rev,
N=2750rpm, Fz=658N Fz=420N
36%.

4.2.2 .

11.
.

-
-

1
-
-

2
-
-

3. .

73

 , ,

.

4.3

Fz
37% f=0.05mm/rev, 48.4% f=0.1mm/rev 36%
f=0.15mm/rev. .
2.
.


,
, , .

(1080), .

74

 1080
=2750rpm
f=0.05mm/rev
136, 30
d=6mm

75

76

77

 1080
=2750rpm
f=0.10mm/rev
136, 30
d=6mm

78

79

80

 1080
=2750rpm
f=0.15mm/rev
136, 30
d=6mm

81

82

83

4.4

( ), , ,
.
12. ( )
.
f (mm/rev)
Fz ()
Fz ()

0.05

210

285

0.10

380

485

0.15

500

658

13. .
f (mm/rev)
(N-m)
(C)

0.05

0.065

90

0.10

0.15

100

0.15

0.30

110

14. .
f
(mm/rev)
0.05

0.10

0.15

84

4.5

).

4.5.1 .

AdvantEdge
:

700
600
500

Fz(N)

400
300

Fz(N)

200
100
0
1

4.4.
Fz.

:
, ,
: f=0.05mm/rev,
N=2750rpm, Fz=285N,
Fz=210N, 26%. f=0.1mm/rev, N=2750rpm,
Fz=485, Fz=380,
21,5%. , f=0.15mm/rev, N=2750rpm,
Fz=658, Fz=500, 24%.
.

85

4.5.2 .

9.
.

1
2
3

4. .

,
( 360 )
,
.

86

 5
5.1

,

.

/.


.
,

.

,
.

..
. ,
.

5.2

87

Al 2024

.

Rapid Mode (SimulationSimulation OptionsGeneral)

20%
. Standard Mode.

,


.

5.3

. ,
.
(Fz), ,
Fz .

AdvantEdge
.
,
,
.

.
AdvantEdge

.
88

5.4

.
.

. ,

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(
) .
, ,
,
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,

.

89


[1]

. , :

, .
[2]

. , . ,

, .
[3]

. . , , .

[4]

. , , .

[5]

A. G. Mamalis, J. Kundrak, A. Markopoulos, D. E. Manolakos, On the finite

element modeling of high speed hard turning.

[6]

Lars-Erik Lindgren, Vahid Kalhori, Mikael Lundblad, achining Simulations And

Their Use In Industry, Barcelona, 2005.

[7]

Vahid Kalhori, Modelling and Simulation of Mechanical Cutting, Lulea

University of Technology, Sweden.

[8]

AdvantEdge Manual.

[9]

TecPlot Users Manual.

[10]

, www.thirdwavesys.com, AdvantEdge.

[11]

Redouane Zitoune, Vijayan Krishnaraj, Belkacem Sofiane Almabouacif, Francis

Collombet, Michal Sima, Alain Jolin, Influence of machining parameters and new nanocoated tool on drilling performance of CFRP/Aluminium sandwich, ScienceDirect, 27
April 2011.
[12]

. , , .

[13]

, ,

, 2003.
[14]

John A. Schey, Introduction to Manufacturing Processes, Mc Graw Hill, Third

edition, (2000).
[15]

, , ...

, 2009.
[16]

. ,

, , , 1998.

90

[17]

S.Kaplakjian, Manufacturing Engineering and Technology Proceedings of the

2000 International Conference on Intelligent Robots and Systems (IROS 00),

Takamatsu, Japan, October 30 November 5 2000.
[18]

http://books.google.gr

[19]

www.matweb.com

[20]

www.en.wikipedia.org

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