Research On Dynamic Modeling Of High Speed Cutting Process And Its Physical Simulation

High speed cutting is an important supporting technology of advanced manufacturing. It is widely used in aerospace, automobile and mould industries because it has lots of outstanding advantages of high efficiency, high precision and low cost compared to conventional machining. However, due to the deficiency of high-speed-cutting mechanism and correlative technical investigations, As a result, the superiority of high-speed-cutting can not be brought into play adequately. Thus, with consideration of developing trend of high-speed-cutting, this paper combined with the high-speed-cutting theory, machine dynamics, cutting experiment, artificial intelligence and computer simulation technology, several research on modeling and simulation of cutting force of high-speed ball end milling with Minimal Quantity Lubrication technology (MQL), machining stability and optimization of machining parameters were conducted and creative contributions are summarized as follows.1. Modeling of ball end milling forces consideration of MQLThe factors of MQL and cutting speed are firstly introduced into milling force model through the milling force coefficients. By means of the central composite design experiments, the milling force coefficients are modeled by adopting the response surface method and BP neural network, respectively. In the geometry modeling of ball end mill cutter, consideration of cusp effect of ball milling, accurate cutting angle range corresponding to different axial cutting depth are deduced. High speed milling force model is established integrate geometry modeling with milling force coefficient modeling, and the simulation results are verified through experiments.2. Combined with ANOVA technique and Taguchi method, different factors analysis including of cutting parameters and MQL on milling forces are performed. And found the sequence of factors effect on it from big to small as axial depth of cut, cutting speed, MQL, federate and radial depth of cut.3. Aimed to ball end mill, the dynamic milling force model taking account of regenerative chatter are deduced, and high speed cutting stability is investigated according to dynamic milling force model, then the stability criterion and the ultimate axial depth of cut are studied by utilizing Lyapunov one order approximate theory. Then, a time domain chatter model is solved resorting to fourth order Runge-Kutta...