Modeling And Characteristics Research Of Cutting Tools For Flank Milling Based On Turbine

With the continuous expansion of market demand, production and performance of motor vehicles and related products is ever increasing. As the main pressure-boosting technology of the car, not only turbocharger improve the performance of engine and enhance engine power, but also improve the fuel burn rate and thus reduce engine exhaust pollution of the atmosphere. With the benefits, better performance of engine and other aspects of the environment, brought by turbochargers of vehicles, the proportion of new vehicles equipped with a turbocharger increased every year.The compressor impeller is a core part of turbocharger and its processing quality and speed directly affect performance and yield of turbocharger, as well as matching to engine. Due to the expansion of compressor impeller’s demand, high-efficiency, high-speed milling has gradually become the main means of monolithic impeller machining. Compare to other milling methods, studies on point milling developed earlier and better. So it is the first to be applied to the monolithic impeller machining. However, point milling has some obvious defects, such as a lower processing efficiency, scratches on surface of monolithic impeller with straight grain surface, and so on. For monolithic impeller with straight grain surface, reducing scratches to improve surface quality can be achieved by the new processing method (flank milling).Flank milling is gradually applied to the actual production process.Based on the theories about cutting tools’ characteristics for flank milling, models with different shapes of the milling cutters are made through computer and stiffness and modal properties were studied with finite element method. Flank milling cutters’ main blade of which helix is the most, locates circumference, parametric equations about helix with equal lead or equal helix angle are founded so as to make models. With the theory of generalized helical motion, relationships between axial motion and rotation motion are made to parametric equations about helix with equal lead. With the theory of space vector method the definition of the spiral angle, differential equations for helixes equal helix angle are founded. By solving differential equations, helix equations with equal angle are founded. Because the same series cutters have same structure and different sizes, three-dimensional parametric models of cutters are made by Pro/E with helix equations. Under the method of finite element analysis, actual situation which includes constraints position and force should be simplified. The models from Pro/E are used in ANSYS to study cutters’stiffness. Finally, since the modal parameters of the tool, such as natural frequencies and formation, have a greater impact on cutting stability and vibration, modal analysis of drum cone cutter offer natural frequency and formation and provide a theoretical basis for dynamic properties of the milling cutter and matching the speed of machines.Studies show cutters’ parametric models make further study on the impact of various parameters on performance of tools more convenient. For flank milling, drum cone cutters’ stiffness and flexibility are better than other cutting tools. Modal analysis results have certain reference value for further study cutters dynamic characteristics.