Wear Simulation Of Ball-end Milling Cutter During Milling Of TC4

Titanium alloy TC4 has high specific strength,good heat and corrosion resistance and other excellent comprehensive performance,in various fields,especially in the aerospace industry.But because of its disadvantages such as low thermal conductivity,high chemical activity and small elastic modulus,titanium alloy TC4 is classified as a typical refractory material.Tool wear in nc milling of titanium alloy TC4 is a prominent problem,which may lead to tool geometry parameter change,cutting temperature increase and low machining efficiency.Ballend milling cutter is regarded as a typical high performance free-form surface machining tool.Tool wear prediction of titanium alloy TC4 becomes very important.Based on the above problems,the ball-end milling cutter of titanium alloy TC4 CNC milling was taken as the research object in this paper.The ABAQUS software was redeveloped by using programming language,and the wear simulation technology of ball-end milling cutter was studied.Based on Isight software,the geometric parameters of ball-end milling cutter were optimized,the structure was improved and the service life was increased.The main work of this paper is as follows:Firstly,the wear characteristics of titanium alloy TC4 processed by ball-end milling cutter under thermal coupling were studied,and the tool wear law in the processing of titanium alloy TC4 was analyzed.According to the machining characteristics of titanium alloy,the wear model suitable for ball-end milling cutter was selected,which laid a foundation for the finite element simulation of ball-end milling cutter wear in the future.Secondly,the UG model was imported into ABAQUS software to analyze the ball-end milling cutter structure and establish its 3d model.Based on the key technology of finite element cutting simulation,the 3d milling finite element simulation model was established to extract the simulation results of milling force and milling temperature in the milling process,and experimental verification was carried out.Then,based on the Fick wear rate model,the secondary development technology of ABAQUS was used to write the tool wear subroutine in Python language.The geometric contour of the ball end milling cutter was updated by using the wear direction of the ball end milling cutter node,and the numerical changes of the wear rate of the front and rear tool surface of the ball end milling cutter were simulated.Finally,using MATLAB GUI module has set up a forecast for the ball end milling process milling cutter abrasion platform,through input the corresponding processing parameters,can quickly get the distribution of tool wear,build the ball head milling cutter geometry parameters based on the Isight integrated simulation platform,the realizing methods of function integration,improve the efficiency of the simulation model and optimization design,the optimum design of high performance cutting tools provides a new method and train of thought.