Study On Milling Impact Of A356 Aluminum Alloy

In the increasingly competitive automotive industry,most of the materials of parts come from aluminum alloy.For enterprises,how to improve the processing efficiency and quality of aluminum alloy parts is the core problem of processing.Further improving cutting parameters may lead to excessive cutting impact and affect tool life,machining quality and machine tool life.At present,the quantitative research on aluminum alloy cutting impact is not deep enough,and can not become the basis for further analysis of the impact of milling impact.Based on this,this paper studies the milling impact of A356 aluminum alloy,discusses and analyzes the characteristics,influencing factors and prediction methods of milling impact,and deeply carries out the quantitative research of milling impact.(1)In order to study the characteristics of milling impact and obtain the characterization method of milling impact,A356 cutting finite element model is established,and the changes of cutting force,strain and tool pressure in forward milling and reverse milling in a cycle are analyzed respectively.According to the analysis results,one cycle cutting force of forward milling is divided into three stages,and one cycle cutting force of reverse milling is divided into two stages.According to the variation characteristics of cutting force in each stage and considering the influence of time on impact,a characterization method of milling impact is proposed: using initial cutting impact force,cutting force peak value and impact time to characterize forward milling impact,The peak cutting force and impact time are used to characterize the impact of reverse milling.(2)The single factor cutting simulation test is designed,the influence of cutting process parameters and tool parameters on milling impact is analyzed,and the influencing reasons are explored.The results show that the spindle speed,cutting depth,feed rate,cutting width,tool rake angle and other factors affect the milling impact.Different milling methods have different influence laws.Under the same cutting conditions,the cutting impact of forward milling is generally greater than that of reverse milling.(3)Based on the cutting impact data obtained from the cutting simulation test,the empirical formula prediction model of milling impact is established with the help of multiple regression method.The statistical principle is used to test the prediction model.The results show that the model has good fitting and reasonable construction,and each parameter in the model has a significant impact on cutting impact.(4)The orthogonal milling test of A356 aluminum alloy is designed.The orthogonal test results are compared with the predicted results,and the coincidence is very high.The results show that the model can accurately predict the vertical milling impact through the empirical formula prediction of milling impact.