| Dry milling with static cooling, which makes the pressed air ionized and ozonic, and supplies the ionized air to cutting area of cool workpiece and tool ,is one of dry cutting technology. It can prolong tool’s life, break the chip and so on. This new technology is to combine metal cutting technology and electrostatic technology. Compare with traditional cutting fluid, the use of dry cutting with static cooling can avoid the disadvantage of cutting fluid in some way, and can reduce product cost.The device of dry cutting with static cooling is designed by researching on the mechanism of dry cutting with static cooling in this paper. Milling tests for TC11 are carried out with the multi-factors orthogonal test method. The milling force of casting TC11 is concluded by regression analysis. And the accuracy of the real motion state which the model describes is verified, the model can predict the milling force in effect. The relation of milling force with cutting depth, cutting width, feed per tooth, and cutting speed is analyzed through the model, which the model provide a justify for the design of tool and the picking of cutting parameterUsing the finite element software-ABAQUS, the finite element simulation of end mill is applied. This paper obtains a more effective image analysis method by analyzing the stress and strain of end mill. The influence of milling parameter with stress and strain of end mill is analyzed. The results indicated that the maximal equivalent stress is located knifepoint, and the cutting speed has the large influence on cutting force under all cutting parameter, which improving the cutting speed can reduce the stress and stain of end mill. At last, analyzing the stress field of cutting proceeding, the instantaneous stress nephogram, the peak stress and the peak stress field which is in each stage are obtained. The real milling law under the dry milling with static cooling is obtained by analyzing the stress and stain in each stage. |
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