Research On The Machining Process And The Process Parameters Optimization For Profiled Roll Pass

Cold rolled tubes have been widely used in aerospace, nuclear power, shipbuilding, automotive, machinery manufacturing and other fields, because of its excellent mechanical properties and physical properties. Cold rolling forming by cold-rolling mill is a very important method of processing cold rolled tubes, and the profiled roll is one of the most important forming parts of cold-rolling mill, so the processing quality of the roll directly decides the quality of cold-rolled tube and production efficiency of mill. As the complex surface of profiled roll pass is required to have high requirement on dimensional precision and surfaces quality, it is too difficult to process and the manufacturing cost has been occupying a larger proportion in the total production cost of high precision tubes. At present, groove surface features and its processing technology are seldom investigated. Among them, especially the research on the optimization of process parameters is less; also do not form an error criterion for groove surface. In this dissertation, by reaching on the complex surfaces of profiled roll pass, the machining process and the process parameters optimization for roll pass, the optimal drilling path and the optimum milling parameters which can fully meet the machining process requirement have been put forward, and groove surface form error has been evaluated, these provide theoretical basis and practical method for the machining of the special-shaped roll pass.On the basis of analyzing groove surface features and detail drawing, curve fitting was done by using Matlab software according to the processing requirements, the parameters such as roll gap opening, width and roll gap were analyzed, and the three-dimensional modeling of special-shaped roll was created by using Pro/Engineer. Analyzing various processing of roll pass,and then designed a machining process which is suitable for the actual production processThen, effects of curvature radius of groove surface and inclination angle of ball end milling cutter on milling forces were analyzed based on the milling experiment. Milling force model of finishing milling and forced deformation cantilever beam model of ball end milling cutter system were established based on groove surface features and milling processes analysis. The relationship between milling force, cutter system deformation and curvature radius, milling parameters was proposed; these provided the reliable theory basis for subsequent processing parameter optimization.In order to improve the machining efficiency and precision of the profiled roll pass, tool path was optimized, mathematical model of milling parameters optimization was established and got the optimal milling parameters. At last, the method of evaluating groove complex surface error was put forward based on groove surface features. Groove surface error analysis results showed that the profiled roll pass processing technology which was proposed in this dissertation can meet the requirements of machining precision and quality.