Large-size Thread Whirling Numerical Simulation And Optimization Of Milling Parameters

The large-size thread whirling machining, which is multi-tool cutting, makes its cutting characteristics significantly distinguish from other conventional cutting methods. According to the new-style thread whirling, optimization studied respectively from the principle and the thermal-mechanical coupling.Firstly, the principle of whirling movement is introduced. From the perspective of geometric, whirling milling machining mechanism is analyzed by using coordinate transformation methods. The transforming relationship between tool profile and thread raceway profile is found. Spiral raceway forming mechanism is elaborated. Meanwhile, it investigates the whirling hard milling technology, such as whirlwind milling chip formation, process parameters, error analysis of the causes, and so on. It builds the foundation for further study.Subsequently, the dynamics and thermal coupling theory of whirlwind is analyzed, and a dynamics model of hard milling system is built. The hard milling cutting deformed milling force and milling thermal model are analyzed. Thermal-mechanical coupling of whirlwind is analyzed by thermal elastic plastic finite element equations.Then, using the special metal cutting special software DEFORM-3D through the establishment of a simplified model of hard milling technology, it combines the numerical simulation with experimental design methods to design orthogonal experiment for milling three elements, also conducts the impact studies of process parameters on the milling force and milling heat through range analysis of simulation results, which obtains the optimal combination of parameters considering the maximum milling heat, the maximum principal milling force, the maximum effective milling force and other indicators.Finally, the hard milling process parameters are studied. Contrary to particle swarm algorithm defects, its performance is improved. Whirlwind milling process parameters are optimized through the application of optimized FMPSO combined with gray relational analysis. Performance test results shows that the proposed method is feasible and rational. It is important for the promotion of hard milling whirlwind.At the end of this paper, the main contents and achievements in this work are summarized, then the unsolved problems are pointed out and an outlook of future research is presented.