Study On Groove Optimization Principle And Technology Of Complex Three-Dimension Grooves Milling Insert

Metal cutting machining is the basic technical method in mechanical industry, and the cutter is the primary tool in the metal cutting machining. The cutter affects the quality and reliability of the mechanical products to a large extent. Along with the development of the insert material and its manufacturing technology, new hard alloy milling inserts with complex grooves come forth continually, and the milling inserts with complex three-dimension (3D) grooves are increasingly applied widely. At present, the grooves of milling inserts developed by domestic and oversea manufacturer are mostly finalized the design with the experiential and experimental methods and shortage of theoretic study basis. The groove has no uniform judgement basis. Thus, in order to solve the cutter disrepair that is the key technical problem in automatization production, and ensure that the advanced manufacturing systems run normally, such as FMS, CIMS, study on groove optimization principle and technology of complex 3D grooves milling insert should be done. The study work has very important theory significance and practical value.In order to improve the cutting capability and reliability of complex 3D grooves milling insert, the force and heat density function mathematical models are built. The force and heat density functions are looked as the boundary conditions and the stress fields, temperature fields and their coupling fields of complex 3D grooves milling inserts are analyzed with the finite element analysis (FEA) method and judged with blurry mathematical theory. The impact disrepair and adhering disrepair of complex 3D grooves milling insert are studied based on experiments. Aimed at the minimal disrepair, the optimization object functions are built. So to provide the basis for the groove optimization CAD system of complex 3D grooves milling insert.Firstly, based on the milling force mathematical model of complex 3D grooves milling insert, the experimental formulas of milling force and contact length and width of cutter-chip are built with a plentiful systemic cutting experiments. Then the force density function mathematical model is built, and is calculated quantificationally to analyse its distributing principle. The studies poivide a basis for the 3D stress field analysis.Secondly, based on the force density function mathematical model of complex 3D grooves milling insert, the stress fields of the waved-edge milling insert and flat rake face milling insert are analyzed with FEA method and judged with blurry mathematical theory. According to the distributing principle of the waved-edge milling insert and force analysis in the cutting periods, the double unison equation is introduced to analyse the stress state of cut-in course with the elasticity mechanics method.Thirdly, the impact disrepair experiments with different grooves and insert materials have been done, the disrepair shapes are compared among the several types of grooves milling inserts. The impact disrepair life cumulating distribution function mathematical models of them are built by the mathematics statistic method and the contrast analysis of the impact disrepair average lives bave been done among them. So to verify the FEA results of the 3D stress field of the milling inserts.Fourthly, based on the milling temperature mathematical model of complex 3D grooves milling insert, the milling temperature of the cutter-chip contact interface is tested by the manual thermocouple method. The experimental formulas are built, which are the average temperatures of the cutter-chip contact area on rake face to time. The heat density function and temperature field mathematical models are built. The heat density functions are looked as the boundary conditions and the 3D temperature fields of the waved-edge milling insert and flat rake face milling insert are analyzed with FEA method and judged with blurry mathematical theory. The mathematical model of the adhering disrepair is studied for complex 3D grooves milling insert. The relations between milling temperature of cutter-chip contact area on the rake face and the maximal adhering disrepair depth are built. According to the maximal temperature on the rake face, the adhering disrepair could be forecasted.Lastly, the heat-stress coupling field between the stress field and temperature field of the waved-edge milling insert and flat rake face milling insert is analyzed to discuss the distributing principle of equivalent stress and its distortion under the coupling condition. Aimed at the minimal impact disrepair and adhering disrepair, the function relations between the blurry judgement results of stress field and the cutting depth, and the function relations between the blurry judgement results of temperature field and the cutting depth are built. The object function is optimized by the optimization theory to provide theoretic basis for designing and developing new grooves.