Machining Technology Of Helical Plate Based On Whirling

Whirling,or whirlwind milling,is an advanced high efficiency machining technology.The cutter on the milling disk rotates by a high-speed while the workpiece rotates relatively slow as an auxiliary motion.Together with the axial feed,required shape is machined by envelope motion.Currently whirling is widely used in manufacture of thread parts.Whirling is characterized by high speed and good surface finish.In certain cases grinding process could be eliminated after whirling.What's more,no cutting fluid is used during the process.Of course,the main advantage of whirling is superior productivity.Helical plate surface parts are common tasks in manufacture,which are widely used in the field of energy and chemistry industry.As a kind of space complex surface,helical plate surface parts are usually machined on four axis or five axis machining centers.Although the geometry accuracy and surface finish requirements could be reached in most cases,but it always suffered by low efficiency and high cost.Because of the advantage of whirling,a new approach to machine helical plate based on whirling is presented in the thesis.Firstly,geometrical model of whirling process of helical plate is built based on the kinematic relationship of cutter and the workpiece.It is determined that the key parameters which influence the shape of the plate are rotational speed ratio of cutter and workpiece,axial feed and eccentric distance of the cutter and workpiece.The method of determining the process parameters for given helical plate is described.Kinematic simulation is conducted in MATLAB which proved the correction of model.Secondly,chip thickness and cutter-workpiece engage are calculated in order to forecast the milling force during whirling.Finally,the variation of cutting temperature during the machining process is studied using DEFORM-3D,and the cutting parameters are also optimized.