Experimental Study And Simulation Analysis Aiming At Milling Process Of Hardened Steel Mould

With the rapid development of modern industry, mold manufacturing has become increasingly requirements on processing efficiency and product quality, and it has an urgent need in dynamic simulation theory and application technology which have practical value. In mold manufacturing, hardened steel is widely used because of its small elongation, low plasticity and easy to form a highly smooth surface. As a dominant method of surface machining, ball-end milling cutter process plays a leading position in hardened steel mold processing with large areas and complex surface. Therefore researching the existing problems and difficulties during ball-end milling cutter of hardened steel can improve its processing efficiency and precision, meanwhile, it is significant to expand range of hardened steel product applications. Based on this, this paper mainly does the following research:According to the characteristics of hardened steel milling, this paper designs a cutting experiment based on parameter optimization and stability analysis of cutting. It analyzes the relationship between the milling process parameters (rotational speed, feed per tooth, row spacing, processing inclination) and the tool vibration. Furthermore, it discusses the effect of milling process parameters on milling stability comprehensively combination of the relationship between milling parameters and workpiece surface quality. Meanwhile, based on the study of vibration characteristics of ball-end milling cutter during hard states milling, this paper establishes geometry model and finite element model of ball-end milling cutter including modal analysis and vibration study.The study of cutter mechanical properties has a great help to analyze the mold milling characteristics. This paper does path experiments to study the advantages and disadvantages of different milling paths. Combining the tool runout and deformation analysis, the ball-end cutter milling force model is established, and model simulation is done as well.Based on experiment study of hardened steel and mechanical characteristic analysis, this paper studies various types of vibration existing in milling process of hardened steel and combines with related theoretical research, then analyzes forced vibration and self-excited vibration synthetically. At the same time, the stability of hardened steel milling is done by analyzing the position relationship of resonance area and stability domain curve in the stability limit diagram.Finally, this paper targeted at the practical application and study of the CNC milling process dynamics simulation. It establishes a dynamic simulation system for the main physical quantities (milling force coefficient, cutting force, flutter stability domain) involved in the ball-end milling process under the premise of dynamics simulation analysis.