| High energy efficiency milling cutter is widely used in high-efficiency processing of difficult-to-machine materials in manufacturing fields such as aerospace and aviation due to their excellent cutting performance.In the high-efficiency milling process,the high-speed,intermittent cutting impact load causes the overall offset of the milling cutter and cutter tooth,and generates high-frequency random vibration,which causes dynamic changes in the interface structure,stress and relative speed of the cutter.Under the long-term cutting conditions,the above-mentioned factors eventually lead to the difficulty of accurately identifying the boundary of the friction and wear area of the tool interface,and the degree of friction and wear and the overall service life of the milling cutter are difficult to accurately predict.Therefore,the distribution and evolution of the friction speed,friction force and energy consumption of the milling cutter interface are revealed.It is of great significance to accurately identify the accumulated friction and wear boundary of the flank face of the milling cutter,realize the precise control of the high-efficiency milling process,and improve the energy efficiency of the cutting process.In this paper,with The National Nature Science Foundation of China（51875145）and The Nature Science Foundation of Heilongjiang Province of China（ZD2020E008）,aiming at the effective control of friction energy consumption of high-efficiency milling cutter,the dynamic characteristics and control methods of friction energy consumption of milling cutter with vibration action are studied in combination with the example of high-efficiency milling.The existing measurement and characterization of flank friction mainly focus on the maximum wear width and ignore the characteristic information of the entire wear boundary of the tooth.The contact relationship between the flank face and the workpiece cannot be accurately described.In response to this problem,this study firstly constructs a dynamic cutting process model of the milling cutter under the influence of uneven distribution of cutter tooth installation errors and random vibration during the cutting process.The multi-coordinate system conversion relationship of the milling system is developed.A method to characterize the friction boundary of the flank face is proposed.Aiming at the difficulty in identifying the instantaneous friction boundary of the existing friction energy consumption model.In this study,a thermal-stress couple field simulation of a high-efficiency milling process is carried out.Combining the effective stress distribution of the flank face of the cutter tooth,the identification method of the instantaneous friction boundary of the flank face is given.It provides a basis for the construction of the instantaneous friction energy consumption distribution function of the flank face.The existing method for solving the friction energy consumption of milling cutters is obtained by undetermined coefficients and through a small amount of experimental assistance,which has large errors and small application ranges.Aiming at the problem of lack of accurate calculation method for friction energy consumption.Based on the dynamic cutting process model of the milling cutter under vibration,this study proposes a method for solving the instantaneous friction speed of any contact point between the flank face and the workpiece.The conversion relationship between the effective stress and friction stress of the flank face under the action of the thermal-stress couple field is constructed.Finally,a solution model for the instantaneous friction energy consumption of the flank face of the milling cutter tooth is formed.The results show that the above model can be used to accurately calculate the instantaneous friction energy consumption of the flank face of the cutter tooth.According to the variation of the effective stress,friction speed and friction force along the characteristic direction,the distribution of the instantaneous friction energy consumption of the flank face of the milling cutter tooth are studied.The time-varying characteristics of the friction speed,friction force and friction energy consumption at the characteristic points are obtained.The evolution of friction energy consumption on the flank face of high energy efficiency milling cutter tooth is studied.According to the identification method of cumulative friction energy consumption boundary and the high-efficiency milling processing experiment.The average relative error between the friction boundary of each cutter tooth calculated by the model and the experiment is less than 20%,which verifies the accuracy of the friction energy calculation model.According to the instantaneous friction energy consumption model of the flank face of the cutter tooth,the scheme design of the factors affecting the friction energy consumption of the flank face is carried out.The response surface model of the friction energy consumption of the flank face is established,and the validity of the response surface model is verified.According to the results of response surface analysis,the significance of the response degree of the flank face friction energy consumption to the design variables is judged.The characteristics of the influence of design variables and their interaction on the friction energy consumption is revealed.It provides the basis for the technological design of the friction energy consumption of the flank face of the cutter tooth.The tool tooth errors,cutting parameters and cutting vibration are used as process design variables for friction energy consumption.A method for judging the control priority of design variables is propose.The milling efficiency is the constraint condition.In the future,the energy consumption of blade friction is the design goal.Combining the influence of design variables and their interaction on the friction energy consumption,a process design method for the friction energy consumption of the flank face is proposed.The effectiveness of the process design method is verified by simulation and experiment.Compared with the original scheme,the new scheme reduces the average value of frictional energy consumption at feature points by 8.2% and the standard deviation by58.5%.The friction energy consumption of the flank face of the new process scheme is significantly reduced. |
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