Cutting Force Modeling And Experimental Research On High Speed Milling Of Hardened Steel With Ball-end Mill

High-speed cutting technology, whose basic characteristics are high cutting velocity and high feed rate, has the advantages of high processing efficiency, high processing quality and low processing costs. It is a hot spot of researching on metal-cutting, and the future development direction of metal-cutting.In this paper, the theoretical model for high-speed milling force using ball-end mill is established. The experimental researching on high-speed milling of quenched carbon tool steel T10 is performed. And the experimental results are compared with the calculation results according to the theoretical model to lay the foundation for finding optimal milling parameters and predicting high-speed milling process for the next phase. The main works of this paper include the following aspects:According to cutting shear deformation theory,a high speed cutting force model with ball-end mill,which is based on the theoretical model of cutting force of oblique cutting in the energy method,is established with the help of the ball milling discrete layer model. The experiment validated the theoretical model.Influence of milling parameters on milling force for high-speed milling of quenched carbon tool steel T10 is analyzed with the single factor experiment.Combined influence of the milling parameters on milling force for high-speed milling of quenched carbon tool steel T10 is analyzed with the orthogonal experiment.According to observing and analyzing for the electron scanning photographs of the chip, my own views on the chip formation mechanism is put forward.The following conclusion can be drawn from the study of this paper:1. The theoretical calculations value is approach to measured data, which shows that the model is basically consistent with the actual milling process, and has certain practical reference value.2. Influence of milling parameters on milling force is important when high-speed milling quenched carbon tool steel T10. When milling speed is lower than a certain value, milling force increases with the increase of milling speed. When milling speed is higher than this value, milling force reduces with the increase of milling speed. Milling force increases with increasing of milling depth. Milling force increases with increasing of feeding speed. Actual machining, reasonable cutting parameters should be chosen according to technical requirements. 3. When high-speed milling of quenched carbon tool steel T10, the chip looks like the tiny granular on the macro perspective, and demonstrates serrated morphology on the micro level. The cutting process shows cyclical of adiabatic shear obviously. And the adiabatic shear band's width is affected by milling parameters. Serrated chip formation is due to the main shear in the primary shear zone periodically adiabatic shear fracture.Researching for high-speed milling cutting force modeling and milling process of this paper has a certain theoretical value and engineering application value.