Study On Surface Morphology And Stability Of Thin - Walled Ball - End Milling Cutter

Vibration seriously restricted the processing quality and production efficiency in the process of manufacturing of thin-wall components, overcoming machining chatter to get ideal surface topography became the one of the challenges of thin-wall components processing. The study focused on the surface topography simulation and the stability prediction of thin-wall components in ball-nose end mill.The surface topography simulation model including geometric characteristics of ball-nose end mill was established. According to different mix of feed rate per tooth fz, path interval p, inclination angle y and initial phase angle difference △θ, the surface topography was investigated through experiment and simulation, which provided the basis for study of surface topography of thin-wall components processing.By establishing stability model of thin-wall components in ball-nose end mill and considering time-variability of dynamic characteristics of thin-wall components processing, the stability limit was predicted, the stability lobes diagram was established and the stability rule was analyzed for different processing phases and location. Stability prediction model was verified by identifying milling force signal and surface quality in the milling test.On the basis of non-vibration surface topography simulation model, the surface topography simulation model of thin-walled curved milling was established by overlapping vibration displacement and ideal displacement, and the influence of vibration to surface topography was researched. We have verified the prediction model, the results show that the measured value is slightly larger than the simulation value, and the measured rule are in agreement with the simulation rule.Aiming at cantilever blade milling, the influence of milling parameters on surface roughness is studied by using the orthogonal experiment that is based on surface roughness prediction model. A multi-objective optimization model of milling parameters was established, and the milling parameters were optimized by considering the constraint conditions of milling stability. The milling experiment of cantilever blade is designed, and the test results verified the correctness of the prediction model and the optimization method in this paper.