Optimization And Experimental Research On Micro-milling Parameter

With the development of precision optics and microelectronics technology in national defense and civil areas, the demand for the micro product is increasing,and higher request for processing quality of components has been proposed. As an important processing method, the micro-milling plays a significant role in this field. But the study on the micro-milling technology is not deep at the present stage. In addition,the development of the micro-milling technology is limited by the condition of the cutting tools and the machine tools.Based on the milling parameter optimization and the milling force modeling of the micro-milling, the research is set by the following aspects in this paper:Firstly, understand the research status at home and abroad about the micro-milling, including the research about the machine tool, processing mechanism, process, and ways of the milling force modeling and the milling parameter optimization. Thus a further understanding will be generated about the micro-milling.Secondly, study the micro-milling force from the perspective of the simulation. Research the conventional milling cutters statics and simple dynamics analysis through ANSYS simulation software. Understand the mechanics properties of milling cutter, inherent frequency and the relationship between inherent frequency and suspended stretch length. The simulation result shows that the tools would not be damaged because of the litter force in the micro-milling. At the same time, it is necessary to reduce the suspended inherent frequency of the tools to increase the inherent frequency of the tools in the processing. The milling process was simulated through the Deform simulation software. The milling force and the stress and the strain of the workpiece were got through the simulation. It shows that the total deformation and the stress conditions of the workpiece are in the inherit range of it. All the simulations are the foundation for the later trails.Thirdly, study the milling force through the orthogonal test method, including orthogonal table design, the establishment of the test conditions, CNC programming and milling process. In the experiment, the brass and the aluminum alloy were milling using respectively 1mm and 0.5 mm diameter of the micro diameter milling cutters, and study the influence of milling force by different milling parameter combination and single factor of milling parameter. The analysis shows that processing brass need bigger cutting force than aluminum alloy because of the differences of the materials. And the analysis also shows that the biggest influence factors of milling force is the axial feeding, second is the feeding speed, and finally the spindle speed. Eventually, get the optimal milling parameter combination of the brass and the aluminum alloy in milling cutter diameter.Fourthly, revise micro milling force model experience formula by the test data obtained in the experiment. The significant test shows that the revised model has much higher significant. Meanwhile, it is proved that the optimal milling parameter obtained in the experiment is the best one by comparing the milling force test value with the calculated value.