Optimization Of High-Speed Helical Mill

The solid carbide mill has been more widely used in the field of high-speed machining at present, but the design and manufacture of the domestic high-speed cutter has a relatively large gap compared with foreign countries. How to optimize the structure of helical mill and improve the carbide mill's properties in the complex conditions is an important research.The main idea of this issue is the optimization of parameters of the helical mill based on the static and dynamic analysis, first, an accurate three-dimensional end mill solid model was built with pro-e software, then the discrete method was used to separate the cutting edge into a finite number of micro-elements, the cutting edge of each infinitesimal edge is simplified as a straight line, the milling force loaded on the micro-element was calculated by oblique cutting model, further the milling force model of the whole cutting edge has been built. Ansys12 was used for static structural analysis with the helical mill, the stress and deformation maps at different time can be obtained and we can easily see the changes. Second, the dynamic characteristic of the mill is important to study the mill, Since the chatter of the helical mill in high-speed machining can result in bad surface roughness and precision of the part and making the mill worn fast.the natural frequencies and modes of the helical mill was obtained by the modal analysis in chart 3, the results can help to adjust the process parameters to avoid the chatter and lay the foundation of the transient dynamic analysis of the mill. Then the vibration characteristics of the helical mill can obtained by the transient dynamic analysis. Finally, by changing the single factor, the affect of the front angle, the back angle and the helix angle on the mill deformation and stress was analyzed. Eight different groups optimal parameters was selected to be optimized. The static structural analysis was applied on the eight different mills. One group of optimal parameters can be chosen as the last result. Compared with the first design, optimal end mill structure can be obtained.