Manufacturing Of Solid Carbide End Mills And Study On Their Friction And Wear Mechanisms

The development of cemented carbide materials, the grinding process of solid carbide end milling cutters as well their friction and wear mechanisms in high-speed milling of aeronautical aluminum alloy are investigated in the present thesis. Aiming at the domesticization of the solid carbide end milling cutters and by means of developing and optimizing the manufacturing technologies for solid carbide end milling cutters including design and fabrication of tool materials, grinding process, the tool performance, tool life and the machining quality are improved, with important theoretical value and practical significance.Based on the analysis of the state of the art for domestic and overseas cemented carbide development, the compositions of the tool material suitable for aluminum alloy machining are investigated and the optimization model is established. The physical/chemistry analysis is conducted on the cutter-workpiece material components, the physical-mechanical properties of the tool materials are tested, from which the reasonable components of tool material were determined. Based on the analysis of the sintering principle of cemented carbide and combining the domestic and oversea advanced sintering process of cemented carbides, a reasonable sintering process is put forward, which is employed to fabricate the cemented carbides bars.Based on the analysis of the grinding principle of the spiral end milling cutter and utilizing the spiral envelope theory, a reasonable mathematical model for grinding movement is established. By analyzing the cutter grinding types and grinding principle and by reference to the production examples of the solid carbide tools, a reliable and practical grinding process is presented, which lay the theoretical foundation for the practical grinding of cutters. The results provide a guidance for the practical manufacturing.For the sake of practical application, the friction characteristics of the cemented carbides-aluminum alloy are investigated via a series of friction experiment. The influence of various factors such as the sliding speed, pressure, temperature as well as the composition of the cemented carbides on the friction performance of the cemented carbides are analyzed. The wear mechanisms of the solid carbide end milling cutter are studied in high speed milling of the aluminum alloy by means of the milling experiments.In this thesis, the experimental and theoretical methods are combined to manufacture the cutter with properties meeting the demand for practical production, promoting the cutter domesticization.