Wear Mechanism And Experimental Study Of High Speed Milling Titanium Alloy With Self-propelled Rotary Cutter

Because of its excellent physical properties,titanium alloy is widely used in the manufacture of key components in aerospace field.However,as titanium alloy is a typical refractory material,problems such as low processing efficiency,severe tool wear and surface quality are common in the processing process.Through the continuous rotation of the blade itself,the self-propelled rotary milling cutter improves the chip removal performance and heat dissipation in the cutting process,greatly improves the service life of the tool,and effectively suppresses the generation of machining surface defects.In this paper,based on the finite element simulation technology and milling experiment,the milling force,tool wear and surface quality of titanium alloy TC11 are studied by using the comparative method.The research content includes the following aspects:Firstly,based on the DEFORM-3D finite element simulation software,the simulation model of TC11 milling with the self-propelled rotary milling cutter is established.The influence of milling speed on the temperature of TC11 milling cutter is studied.The temperature of TC11 milling with the self-propelled rotary milling cutter and the fixed circular milling cutter are compared under the same conditions.Secondly,the experiment of cutting TC11 with the self-propelled rotary milling cutter is designed,and the chip flow and macro and micro morphology of TC11 with two kinds of milling cutters are studied.It is found that compared with the fixed circular milling cutter,the self-propelled rotary milling cutter has better chip removal performance and better chip shape consistency.The influence of milling parameters and tool wear on the milling forces of the two kinds of tools is analyzed.Then,a comparative study on tool life,tool wear process and mechanism ofTC11 milling with two kinds of tools is carried out.Compared with the fixed circular milling cutter,it is found that the wear of the rake and flank face of the selfpropelled rotary milling cutter is more uniform,the wear rate is much smaller,the tool life is longer,and there is no crater wear.With the progress of cutting,the wear mechanism of the self-propelled rotary milling cutter gradually changes from abrasive wear mechanism to fatigue wear mechanism,and finally,with the generation of hot cracks,the blade peeling failure occurs;The fixed circular milling cutter causes the cutting edge to collapse under the combined action of adhesion wear,diffusion wear,oxidation wear and other mechanisms.At last,the model of machining residual height of the self-propelled rotary milling cutter is established,and the calculation formula of surface roughness of the self-propelled rotary milling cutter is given;The influence of milling parameters on the surface roughness and surface morphology of the self-propelled rotary milling cutter is studied;The influence of tool wear on the surface quality of two kinds of milling cutters is compared and analyzed.It is found that the surface quality of the fixed circular milling cutter is better than that of the self-propelled rotary milling cutter in the early stage of milling.In the whole machining process,the surface quality of the self-propelled rotary milling cutter decreases less.