Finite Element Modeling And Experimental Investigation On Helical Milling Hole-making Process Of Titanium Alloy

With its excellent performance, titanium(Ti-6Al-4V) material has been widely used in aerospace. However, the hole making technology of titanium alloy, low thermal conductivity of the material itself, the chemical activity, low modulus of elasticity reason has always been a hot topic, the quality of hole and manufacturing efficiency is difficult to meet at the same time. Helical Milling hole processing system as a new technology is an ideal system borehole technology about titanium, composites and other difficult materials. In order to understand the helical milling process, it is necessary to carry out the work of cutting process simulation study. In this paper, the special tool geometry parameters of helical milling were optimized and finite element analysis of helical milling process were studied, the main contents include the following aspects:Firstly, in the analysis of the kinematic helical milling process, based on the proposed helical milling cutting process is a combination of drilling and milling. Helical milling for special tools to design, build a three-dimensional model of a dedicated tool. Helical milling special tool geometry parameters were analyzed on cutting performance, the whole factor tests were studied on different tool geometry parameters. With the goal to optimize the cutting force, using of artificial neural network model of tool geometry parameters and ultimately determine the optimal geometry optimization tool.Secondly, the optimized geometry of the tool as a reference tool to establish a simplified three-dimensional model and applied to the finite element simulation of helical milling process, analyzes the choice of the constitutive model of titanium alloy, the failure criterion related to modeling, friction models key technologies. The successful helical milling process was simulated, and the raw data of cutting force were obtained by simulation analysis.Finally, experimental verification and analysis of the results of the finite element model, in order to verify the effectiveness of the finite element model and using of single-factor test method, different cutting parameters were applied in the helical milling test, cutting forces and experimental results were compared with the simulation. The surface residual stress test were carried out, and the simulation of machining the workpiece surface residual stress and residual stress analysis. The validity of the finite element model was test and verified from the cutting force, stress and chips.