Study On The Theory And Application Technology Of Cut-In Disrepair With 3D Complex Groove Milling Insert

The industry of the heavy machinery, automobiles and the power station equipment has become the pillar of our country. The manufacture of the huge and complex parts is the core technology of the manufactory. Most of their materials are difficult-to-cut materials. The characteristic of these materials is high in rigidity, strength and toughness. Therefore, the disrepair of the cutting tools is severe when machining. Both the cutting tools life is short and their efficiency of production is low. The disrepair of cutting tools is one of the key technigues and is a problem as well, particularly in automatization production of FMS,CIMS. Looking up a great deal of literature, the study of the cut-in disrepair is all about the flat-groove milling insert. And the study of mechanism of the cut-in disrepair for 3D complex groove milling insert seldom reported. In recent years, a great deal of 3D complex groove milling insert has been applied to the machining industry. But, the study of the theory is droped behind the practice. The theory base on the application and development of the 3D complex groove milling insert should be enhanced.This paper described the moving contact theory of the 3D complex groove wave-edge milling insert. The mathematical model of nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is deduced. The excellent mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. The simulation system of waved-edge milling insert cut-in style is studied. The milling inserts and cutting tools with 3D complex groove are developed. Thus, the disrepair problems of cutters are solved.Based on mathematical analysis and simulation experiment, the front face equation, the front face moving equation, the cut-in contact equation, the join line equation and the shape of cutting field equation for 3D complex groove wave-edge milling insert are deduceded. And the contact theory of 3D complex groove wave-edge milling insert is formed.The nine new kinds of contact forms of the 3D complex groove wave-edge milling insert is put forward. The changing quantityδof contact angle of the front face is imported. Thereafter, the mathematical model of thr nine kinds of cut-in style discriminant for the 3D complex groove wave-edge milling insert is established.The mathematical model of the cumulate function of impacting disrepair life is founded on various cut-in styles. That conclusion of the cumulate function of impacting disrepair life obey to the function of Weibull is reached. The cut-in style of the 3D complex groove wave-edge milling insert is choosen for best. The excellent cut-in style is the U style, and the V style, T style and S style are followed in order.The simulation system of waved-edge milling insert cut-in style is studied. Based on UG platform, under UG offered environment, with UG/Open API and VC++ software, the waved-edge milling insert cut-in simulation system is created. According to various parameters, by using modeling technology, the process of waved-edge milling insert cut-in can be simulated. The new method for studying 3D complex groove milling insert cut-in disrepair has been given.Based on the mechanics and materials science, optimization technique of 3D complex groove wave-edge milling insert is studied. Various workpiece materials, cutter materials, processing conditions and loading, through experiment both in laboratories and in factorier, by analyzing cutting force, chip shape, cutting life, failure form and insert material, optimization model of stress field for 3D complex groove milling insert is developed. The insert groove and geometric parameters, together with material are optimized. The series of 3D complex groove milling insert are developed.