High-efficiency Milling Process Of Titanium Alloy Integral Impeller Based On Cutting Load Balancing

Due to many advantages such as small size and light weight,the titanium alloy integral impeller is widely used in turbine machinery such as aircraft environmental control system centrifugal fans.Its diameter is generally about 150 mm,under extreme environments such as sand and dust,high temperature and high pressure.It puts very strict requirements on the processing quality,and titanium alloy is a typical difficult-to-process material.The tool wears seriously during processing,the processing efficiency is low,and the processing accuracy is not easy to guarantee.This has brought great challenges to the research on the efficient milling process of the integral impeller.In view of the above problems,this paper has carried out the following research work on the optimization of milling parameters of the overall impeller:The most important physical quantity in the physical simulation of the CNC milling process is studied: milling force.For the tools used in the milling of the entire impeller,the milling force models of cylindrical spiral end mills and ballend mills are established respectively,and they are obtained through cutting experiments.The milling force data,the identification of the cutting force coefficient,and the comparative analysis of the test data verified the accuracy of the model.It not only provides important constraints for subsequent roughing milling parameter optimization,but also an optimization goal for finishing milling parameter optimization.Based on the modal test analysis of the tool-machine tool system and the dynamic model of the milling process,the milling stability is predicted.Aiming at the process system composed of two kinds of tools and machine tools respectively,the zero-order frequency domain method is used to draw the stable lobe diagram,combined with the milling dynamics model and the dynamic milling force model to perform time domain simulation,and explains how to use the xy plane milling force The simulation results of tool tip displacement predict the stability of the milling system,which not only verifies the accuracy of the stability leaflet diagram,but also provides an important basis for further optimization of the cutting amount.To optimize cutting parameters,first perform geometric modeling of the workpiece and tool,complete the geometric simulation of the machining process based on Boolean operations,and then,combine the geometric simulation and physical simulation to establish a virtual machining system,and then carry out the titanium alloy based on the material removal rate and cutting load The optimization of CNC milling processing parameters of the integral impeller provides an important foundation for improving the machining efficiency of the overall impeller and improving the machining quality of the blade surface.Specifically,the roughing stage is based on the particle swarm optimization algorithm to maximize the material removal rate,and the cutting load constraints are considered to optimize the feed speed and spindle speed;the finishing stage is based on the feed speed iterative optimization algorithm to cut the load Equalization is the optimization goal,considering flutter stability and optimizing feed rate.The titanium alloy integral impeller machining test was carried out.Using the NC code optimized by the virtual machining system,the titanium alloy integral impeller specimen was processed.The surface quality of the processed blade was measured and the cutting process time was recorded.The result showed that the surface quality met the designed tolerance and machining efficiency were increased by 10.2%,which verified the accuracy and reliability of the milling parameter optimization results based on the virtual machining simulation system.So far,the high-efficiency milling process of the titanium alloy integral impeller of the centrifugal fan has been completed.