The Optimization Of High Feed Milling Insert Upon Free-cutting Theory

High Feed milling (HFM) concept conforms to the society trend pursuing the efficiency for the biggest profit, it combines little cutting depth with high feed per tooth to protect tool and obtain higher metal removal rate, To implement the concept, many enterprise focus them on Research and Development for High feed milling insert.ASR high feed milling insert for Hitachi is derived from the circular blade, Circular arc cutting edge would inevitably cause interference of chip ejected from different segments of the cutting edges. The interference will increase the cutting power consumed and accelerate the tool wear. To solve this problem effectively, this paper uses free-cutting theory to optimize this type of high feed insert, changes the shape of rake face to eliminate the interference of chip, and utilizes the finite element simulation software (DEFORM-3D) to simulate the process of milling to test cutting performance of the milling insert before and after optimization, then analyses contrastively the cutting force and temperature of blade and distribution of tool wear. The main contents of the study as follows: Studying the free-cutting theory in depth, this paper uses theory of cutting tool with cylindrical rake to optimize ASR high feed milling insert, and models the milling insert with the software PRO-E, then establishes3-D coupled rigid-plastic finite element simulation model, including determining material model, chip separation criteria, contact friction model, wear model, boundary conditions and mesh generation etc.The simulation results are analyzed deeply, including the formation of the chip, chip morphology, cutting force, temperature, tool wear, etc. this work considers feed and cutting speed how to influence cutting force, temperature and tool wear, then explains these phenomenon with correlation theory, sets the contrast group and optimizing group to inspect the performance of optimized milling insert, conclusion is that, under the same cutting conditions, optimized milling insert has less wear than the contrast group because of the high strength, heat faster, longer cutting edges, and cutting force is also smaller. This conclusion will provide direction and theoretical support for design improvement of this type milling insert.