Modeling And Simulation Of Milling Force Of Ball-end Mill In Multi-axis Linkage NC Machining

Multi-axis linkage machining technology with high precision, fewer setupsand other advantages, become an irreplaceable means of complex surfacemachining.NC machining simulation has become the essential process of NCmachining, mainly through the simulation process, it can predict conditions andresults that may occur in the processing, optimize the machining parameters,improve processing efficiency,The research on NC machining geometry simulation has been very mature,many simulation software have emerged, and the research on physical simulationis relatively few, where the simulation of milling force is the key part of physicalsimulation of NC machiningIn this paper, through analysing the spatial geometry movement of multi-axisprocessing and extracting the tool path file parameters, detailed describe thegeometrical characteristics of the tool and the workpiece under spatial attitude,build the Multi-axis machining milling force simulation model, and furtheranalyze the effect of cutter deformation effect on the milling force, and providedscientific basis for the prediction of multi-axis NC milling force.Through the analysis of tool path files, the paper has established themathematical expression about related parameters in the process of multi-axismachining，it also has established the theoretical model and simulated onmilling force in Multi-axis machining. The infinitesimal milling force model inany points is built with Instantaneous rigid model made by Altintas. On this basis,the instantaneous contact zone of tool and workpiece in multi-axis processing isanalyzed by using the geometry of space, coordinate transformation based on therelationship between the position of space coordinate system is completed, and amulti-axis milling force model under ideal state is built.Deformation of cutting tool system has an important influence on the millingforce and surface quality. The tool system is simplified into a three-stage model of the cantilever beam, the mathematical model of deformation of cutting tool isestablished by using the mechanics of materials, further analyze the influence oftool deflection on the instantaneous chip thickness, and improve the milling forcemodel, it provide a theoretical basis for further research on physical simulation ofNC machining.Accuracy of milling force coefficient models directly affect the precision ofthe milling force model, The paper is proposed the method of segmentedidentifying milling force coefficient is provided. According to the knife shaftangle range, select different milling force coefficient. Aiming at the milling forcemodel which established in this article, the curve drive control cutter shaftswinging in linear feed cutting process, for example, then experiments areperformed on the milling force models which has been established, the resultsshow that the milling force model which is proposed in this paper accuratelypredict the change of milling force in the actual processing.With the help of mixed programming technology of matlab and vc++,thepaper aiming at the Multi-axis machining milling force prediction model which isestablished, on UG platform develop the Multi-axis machining milling forcessimulation system which achieve the integration of3D modeling, numericalcontrol programming, Path simulation, Milling forces simulation seamlessly. Itprovide convenient conditions for integrated simulation of geometric andphysical simulation of NC machining simulation.