Design Of Helix Angle Of Cutting Edge Of Multi-edge And Micro-tooth Milling Cutter Based On CFRP Oblique Cutting

Carbon Fiber Reinforced Plastics(CFRP)have excellent properties such as high specific strength and specific modulus,and are widely used in many fields.In order to satisfy the forming and assembly requirements of complex CFRP parts,it is usually necessary to perform secondary milling.The helix angle of cutting edge is an important geometric parameter for the design of multi-edge and micro-tooth milling cutter,which can affect the CFRP milling quality.Reasonable design of helix angle of cutting edge will have practical significance for high quality and efficient milling CFRP.The research contents of this paper are to simplify the micro-tooth cutting edge of multi-edge and micro-tooth milling cutter as oblique cutting.The theoretical model of single-fiber oblique cutting is established to obtain the deformation state of the fiber under different inclination angles of cutting edge.The three-dimensional microscopic finite element simulation model of oblique cutting is established under the same state.The results from the simulation model and the theoretical model are compared,including the comparison of the position of the fiber to the destruction and the deformation magnitude at the position.According to the tool structure relationship of the multi-edge and micro-tooth milling cutter,the value of inclination angles of cutting edge is selected.The CFRP unidirectional laminate tests of four typical fiber directions are carried out to analyze the influence of inclination angles of cutting edge on the machining quality.The suitable value of inclination angles of cutting edge for machining CFRP is obtained,which can be used for the design of the helix angle of cutting edge of multi-edge and micro-tooth milling cutter.And it is verified by the multi-edge and micro-tooth milling experiment in the same state.The specific work of this paper is as follows:(1)The single fiber theoretical model of three-dimensional strong support side surface of CFRP unidirectional plate of 90° fiber direction with oblique cutting is established.The deflection curve of the fiber in all directions and the position where the fiber fails are obtained under the different inclination angles of cutting edge.(2)The three-dimensional microscopic finite element simulation model of oblique cutting with the same state as the theoretical model is established.The theoretical and simulation results are compared.Furthermore,through simulation calculation,the influence of the tool with different inclination angles of cutting edge on the material removal of CFRP microscopic components is obtained.(3)Through the macroscopic oblique cutting experiment of four typical fiber angle CFRP unidirectional plates,the influences of inclination angles of cutting edge on the microtopography of the machined surface on the both sides and the machined surface roughness are analyzed and discussed.The inclination angles of cutting edge for processing are analyzed and obtained.Further,the helix angle of cutting edge is designed based on the optimized result of the inclination angles of cutting edge.Corresponding multi-edge and micro-tooth milling cutters manufactured using these parameters.Finally,a series of milling experiments are carried out for verification.