High Speed Milling Tc4 Titanium Alloy Thin-walled Frame Parts Processing Research

TC4titanium alloy, for the characteristics of high specific strength, heat resistance and good corrosion resistance and other excellent properties, has been widely used in aerospace field. High-speed milling thin-walled frame parts, it needs to take a complex process of removing large amounts of material from a single piece of billet,and it must be very difficult. In order to improve the processing quality and efficiency of the aerospace thin-walled frame parts, the study is of great significance.Based on the analysis of the orthogonal test result of the cutting force, the order of cutting parameters which had impacted on the cutting force, was feed rate, radial depth of cut, axial depth of cut, cutting speed. In the range of0.04mm/z-0.1mm/z, with feed per tooth increasing1times, the cutting force increased more than50%. In the range of0.4mm-1.6mm, with the radial cutting depth increasing1times, the cutting force of nearly increased1times. In the range of2mm-8mm, cutting force with axial cutting depth increased.Within60.2-120.5m/min,the variation of cutting force changing along with the cutting parameters met the cutting theory. The cutting force simulation was carried out with DEFORM-3D software,and it had verified that the proposed method was correct.According to the analysis of the result of the single factor test and orthogonal test, the variation of the surface roughness of high-speed milling TC4titanium alloy changed with the cutting parameters was displayed. The arrangement of the factors,based upon the degree of impact on the surface roughness,was feed rate, spindle speed and axial depth of cut. Results showed that, in the range of200.9-401.9m/min, surface roughness decreased firstly and then increased, and when the speed was greater than351.2m/min, titanium alloy surface appeared droplet adhesion phenomenon. With the increase of feed rate increased, and surface roughness increased. In the range of0.1mm-0.6mm,Axial depth of cut had little effect on surface roughness. The orthogonal designed conditions the experience formulas of surface roughness have been obtained,and it had verified that the proposed method was correct.The relative technical parameters and cutter paths were optimized,with ANSYS software to predict thin walled frame deformation. The channel, machining thin-walled frame part,was put forward,and eventually by use of UG, the simulation for the main machining process of the thin-walled frame part was realized. Through the simulation test, the optimal cutting parameters could greatly improve the processing efficiency.