Virtual Design Of Milling Insert With 3D Complex Groove

Indexable milling insert with 3D complex groove has better cutting performance than insert with plane face and has the tendency to replace insert with plane face. However the kinds of milling insert with 3D complex groove are few. The groove is modeled by experience and there is a lack of theory basis. To get better groove with cutting performance and better temperature field, the theoretical and experimental researches of milling temperature field, evaluation and reconstruction of complex groove, wear and fracture of tool and optimization of milling process are studied comprehensively and profoundly.1. The heating density function is established by heat source method based on heat transfer theory, and the model of heating density function and surface heating density function of milling insert that the groove parameter is known could be achieved, which establishes the target function for the groove function and the boundary condition for finite element analysis for temperature field.2. Considering each influencing factor, the model of fuzzy comprehensive evaluation for temperature field is established based on fuzzy mathematics theory. The two-band fuzzy comprehensive evaluation is applied. Not only all of the influencing factors are considered but also all the information of every evaluation stage is reserved, which makes the evaluation result accord to the practice. The comprehensive evaluation of wave insert and milling insert with plane face is processed.3. Heating density function being the target function, the reconstruction algorithm driven by the fuzzy comprehensive evaluation for temperature field is developed based on the genetic algorithm, which could realize the real-time reconstruction of 3D complex groove and establishes the frame of the groove reconstruction technique.4.The virtual design system of milling insert with 3D complex groove is developed preliminarily. The favorable man-machine interaction interface is also developed to process the fuzzy comprehensive evaluation for temperature field and groove reconstruction of milling insert.5. The mechanism and reason of wear and fracture of milling insert are discussed. The forming and mechanism of typical wear and fracture is analyzed. The target function for optimization of milling parameters is established, and the process parameters are optimized by genetic algorithm.