Simulation And Research Of Helical Milling Process And Surface Morphology

Compared with the traditional hole-making methods,the helical milling method shows strong advantages and has a very broad application prospect in the field of aerospace.An intensive study of the helical milling process is meanningful to improve the understanding of this new hole-making method.At present,there is little research on the cutting process of the helical milling method and few studies concentrate on machined surface morphology.In this paper,some fundamental researches on helical milling process were carried out by means of simulation and modeling.The main work is as follows:(1)Based on the study of the kinematic of helical milling,the machining process was conveniently simplified and modeled in SolidWorks.The 3D surface morphology of the uncut material during the helical milling process was obtained.The 3D surface morphologys of the uncut material under different machining parameters were compared,and the result showed that there were four different types of surface morphology.Based on the principle of geometry formation of uncut material surface morphology,a calculation model of cutting depths of different cutting edges on the helical milling specialized tool was established.The variation of cutting depths in different cutting position under different machining parameters was studied.(2)On the basis of the calculation model of cutting depths,the cutting material volume of different cutting edges was calculated.The change law of cutting material volume under different machining parameters was studied.The percentage of cutting volume of different cutting edages was calculated.The change law of cutting volume proportion under different machining parameters was also studied.The volume ratio between material volume removed by the front cutting edge and the periphery cutting edge is calculated,and the variation of drilling and milling ratio with the machining parameters was studied.(3)The motion trajectory equations of cutting micro-element on the tool under the ideal circumstance,tool eccentricity,spindle eccentricity and tool inclination were deduced.Considering the particularity of the machined surface in the helical milling process,the modified Z-map model was presented to build the simulation model of the machined surface morphology.As an example,the influence of tool eccentricity,rotation speed and revolution speed on the machined surface morphology was studied.(4)Based on the simulation model of the surface morphology,the calculation method of the surface roughness was presented using surface topography simulation results.the variation of surface roughness with rotation speed,revolution speed and eccentricity was also studied.Helical milling experiments were carried out to verify the effectiveness of the roughness getting from the simulation method.