Research On The Influence Of The Formed Geometry Structure Of The End Mill Groove Flute On Tool Service Performance

Milling processing is widely used in high-end manufacturing industries such as aerospace,rail transit and automotive molds because of its good complex surface processing capability.However,the milling process is prone to machining vibration,deformation,tool rapid wear and other processing defects,restricting the milling efficiency and processing quality improvement.And the flute groove is the key structure that affects the mechanical performance of the tool,therefore,studying on the influence of the flute groove structure parameters on the key performance of the end mill is beneficial to improve the overall life and cutting efficiency of the end mill.The flute groove is a space complex spiral surface,the current modeling method is to use straight lines,arcs and other simple lines to simplify its cross-sectional structure,ignoring the characteristics of the cross-sectional line of the flute groove as a spline curve,it does not match with the actual situation.therefore,this paper proposes to model the tool based on the end mill forming process,which can be established smooth,complete end mill flute groove model that matches the actual situation.Then use the finite element model to study the influence of the flute groove structure on the performance of the end mill.At the same time,related experiments are designed,and the simulation and experiment are compared to verify the reliability of the simulation results.The specific research content of the paper is as follows:1.By grinding along the spiral line of the grinding wheel with known configuration,to build the flute groove model,and then the structure of the Gash face and the back-face on the end face is modeled by the Boolean operation of the "cutter",finally the 3D model of the end mill is built by the forming process.And by the forming process of the end mill on the blank rod material with the end mill rake face,groove width,groove depth and transition curve of tool as the structural variables to design 19 end mills with different flute groove structure.And import the end mill model into the ABAQUS software to divide the mesh and perform finite element analysis on the tool.2.Set up the finite element milling model of the End mill,and compare the simulated chips with the actual chips to verify the accuracy of the simulation results.Study the influence of the chip flute structure variables on the milling force of the tool by the simulation model,which provides a theoretical reference for optimizing the cutting performance of the end mill.3.The mechanism of influence of the end mill flute groove on tool stress and deformation is analyzed in the Euler-Bernoulli stiffness equation.Set up the finite element model to study the influence of each structure variable of chip flute on the maximum equivalent stress and maximum deformation of the tool,which provides a theoretical reference for optimizing the static mechanical properties of the end mill.4.Set up the dynamic simulation model of the End mill,and compare the simulation results with the existing experimental results of related papers to verify the accuracy of the simulation results.Study the influence of each structure variable of the chip flute on the natural frequency and dynamic stiffness of the tool by the simulation model,which provides a theoretical reference for optimizing the dynamic characteristics of the end mill.