Process Optimization And Surface Quality Evaluation Through High-speed Precision Micro Cutting On Ti-6Al-4V

This paper discusses influence rule of cutting factors on surface quality and cutting force and evaluates processed surface quality as well as optimized Ti-6Al-4V alloy high-speed micro cutting technological parameter through high-speed precision micro cutting experiment on Ti-6Al-4V alloy, aiming at acquiring optimal technological parameter when doing highspeed micro cutting on Ti-6Al-4V alloy.Make static simulation analysis to micro milling cutter through simulation software such as ABQUS and ANSYS, which leads to the conclusion that the natural frequency of micro milling cutter decreases as the overhanging volume of cutting tool grows and that high-speed micro cutting procedure would not cause damage to micro milling cutter. Simulate high-speed micro cutting procedure on Ti-6Al-4V alloy through simulation software such as Deform-3D, which reaches the conclusion that stress and strain values and the maximum stress and strain value are all within the allowable range, which verifies rationality of the experiment. This has laid a theoretical basis for follow-up study.Analyze influence rule of cutting factors such as spindle speed, cutting depth, feed rate and tool overhang to surface roughness and cutting force through high-speed precision micro cutting Ti-6Al-4V alloy single factor and orthogonal experiments, which concludes that spindle speed has the most remarkable influence on value of surface roughness Ra, Rz and cutting force, tool overhang has remarkable influence on surface roughness and that cutting depth has remarkable influence on cutting force in the process of high-speed micro cutting.Analyze and formulate evaluation method on surface quality of this paper based on the theory of surface integrity to evaluate and analyze the processed surface quality of Ti-6Al-4V alloy. Use orthogonal experimental method to optimize high-speed precision micro cutting procedure on Ti-6Al-4V alloy and leads the conclusion through the analysis of experiment parameters: surface roughness Ra is 0.057μm and Rz is 0.672μm when spindle speed is 40 000r/min, cutting depth is 0.05 mm, feed rate is 90mm/min and tool overhang is 14 mm when doing high-speed precision micro cutting on Ti-6Al-4V alloy with overall micro-diameter milling tool with a diameter of 1mm. Both the experiment result and Sample processing have verified accuracy of analysis.