Cutting Force Modeling And Simulation System Of NC Milling Process

Milling force modeling and simulation of NC milling process is an important research in virtual manufacturing technology and a basis for physical simulation of milling process.By means of differential geometry theory, metal cutting theory and cutting dynamics, machine tool testing technology and computer simulation technology, the modeling and simulation of milling force were systematically studied using cylindrical helical end mills and ball-end mills as the a research object, The contributions may be summarized as follows:1. Milling force model of the cylindrical helical end mills is established. Based on presenting geometrical features of cylindrical helical end mills through the differential geometry theory, a local milling force model was proposed using three-dimensional triple cutting according to the relationship between cutting area and milling cutter instantaneous power theory. Then, the total milling force model was formulated.2. Milling force model of the ball-end mills is established. Local milling force model and the whole ball milling force model was established according to combine theoretical analysis and experimental study, the model established work was based on the simplified milling force theory.3. Test research on the milling forces of cylindrical helical end mills and ball-end mills. First, the orthogonal experimental has been designed, and a cutting tests was carried out on high-speed five-axis NC machine tools. Finally, the measured cutting force data was obtained, these work took a basic work for milling force simulation.4. On the basis of physical simulation model of milling force, the physical simulation software MPSS V2.0 in the NC milling process was developed based on MPSS V1.0 and Visual C++6.0, A simulation system for milling process with the functions that contains read milling force data, edit parameter, identify coefficient, data generate, two-dimensional and three-dimensional graphics display and so on.5. Database technology was applied to the NC milling process physical simulation system. In order to save on the trouble of input parameters during the milling process simulation, dialog boxes to input variety parameters were added in the simulation system. These dialog boxes were linked with database system to make it possible for automatic storage, filling and editing of parameters.The work in this thesis will lay a solid foundation for enriching the virtual manufacturing theory, improving the milling stability and machining quality, and developing the practical physical simulation system of milling process. Moreover, this work would be of great significance to practical operation of NC machining center in engineering.