Study On End-milling Cutter Rigidity In High-speed Milling

The concept of high-speed cutting (or high-speed machining) started in 1931 with0 German Dr. C. Salomon's experimental research, "with the proper speed of the cutting (about 5 to 10 times faster than the routine speed) to cut, the temperature on the cutting edge will be reduced, so the productivity of processing can be improved through high speed cutting". For over 70 years, people have kept on exploring valid, suitable and reliable high-speed cutting method, and applied them in industry gradually. High speed cutting refers to the vertical milling at the high spindle speed and high feed speed, which is widely used in manufacturing industry of aerospace, mould processing, automobile part and the accurate-part production, etc. It has been applied in free-cutting metals such as aluminum alloy and copper, hardened steel, titanium alloy and high-temperature alloy, and the carbon fiber plastics etc. For example, in the production of the aluminum alloy plane parts, the curved surface and the structure are complicated, the material remove amount is up to 90%- 95%, and adopting high speed milling can improve production efficiency and machining accuracy. In the mould industry, high-speed milling can be used to process the hardened steel parts whose hardness is greater than HRC50, so in a lot of situations the electric spark processing deburring by hand can be omitted. High-speed milling can be applied to meet the demands of part size, shape and the surface roughness after the heat treatment.The vertical end milling cutter becoming crooked and out of shape is the main reason of the machining error of the parts. The amplitude of the deformation depends on the rigidity of the milling cutter. The worse the rigidity, the easier the cutter todeformation and to cause milling vibration. Therefore, the machining accuracy of the work piece is bad. The diameter of the milling cutter, the number of the spiral and the suspending length of the milling cutter deform and inertia couple mathematics. The aim of the essay is to make sure the most suitable length stretching out of the tool adapter during the process of high speed milling to reach the higher cutting machining accuracy. Besides, if the suspending length of the milling cutter and the static as well as dynamic rigidity in the process are different, the vibration is also different. Therefore, the roughness of surface is affected. The elements that affect the roughness of surface include the rigidity of the milling cutter and the condition of cutting. Therefore, using the coordination of the suspending length of milling cutter with all kinds of cutting processes to do the experiment, one can compare and validate the established mathematic models. The conclusion can be used to guide the practical production, which has high practical values.