Dynamic Milling Force Model And Milling Parameters Optimization For The Ruled Surface In Five-axis Flank Milling

Milling force can analyze the stability of the machining process,so it is an important parameters to prevent milling chatter.In the process of five-axis finishing ruled surface impeller,an extension shank cutter is usually used to avoid interference due to the narrow channel,and the attendant problems are the tool rigidity declines.However,the tools ’ dynamic characteristics are often ignored in the process of milling force simulation,which will affect the estimate of the milling stability.So it is very meaningful to study the dynamic characteristics and optimization method about the milling process.Firstly,a model was built about milling force coefficient and edge milling force coefficient.Milling forces of the X,Y and Z directions were measured by orthogonal experiment.Then the average milling forces were calculated with the measured instantaneous milling forces.The unknown coefficients in the coefficients model can be calculated reversely using the average milling force.In the end,the milling force coefficient and the edge force coefficient were obtained.Secondly,an instantaneous milling force model was built which considered the dynamic displacement response of the tool in five axis flank milling.An instantaneous undeformed chip thickness model was studied in the case of considering the tool dynamic milling response.Dynamic milling forces were calculated for the ruled surface which combined the dynamic chip thickness model and ball milling force model.Finally,the dynamic displacement and dynamic milling force were simulated for ball end tool using Matlab software,and the simulation results were analyzed.Thirdly,the deformation of the flexible cutting tool was studied in the process of side milling.A machining trajectory and related machining parameters were selected to calculate the dynamic milling forces in the direction of X,Y for eachanalysis time according to the calculation method of dynamic milling force.In the ANSYS software,milling forces in three directions were loaded to the finite element model of ball end milling tool.Deformation was analyzed by post-processing for the ruled surface side milling.Finally,the milling parameters were optimized which were aiming at tool’s dynamic displacement in side milling blade.The milling parameters that affected dynamic displacement were trained and optimized by using BP neural network and particle swarm optimization algorithm during the ruled surface side milling.The processing experiments were done with the optimized parameters.The blade roughness tests showed that the surface quality was obviously improved which proved the feasibility of the optimization method.