Study On Cutting Force Simulation Of Mould Corner Machined With Flat End Mill

The mould is a key object of study in the field of NC machining, and it iswidely used in automobile, engineering equipment and aerospace fields. Mouldusually uses materials of high hardness which is difficult to machine,especiallywhen the tool is machining the corner, the milling force fluctuation increasesobviously, the vibration between the tool and workpiece increases significantly,and the service life of the cutter is difficult to guarantee. All these problemsbring certain difficulty to the mould processing, aiming at the above problems,this dissertation carries out the relevant research.First of all, the corner milling thickness calculation model is established. Inthe study of90°corner milling process, three stages of cutting is divided on thebasis of tool path and the corner appearance characteristics, and this three stagesof cutting phase is linear cutting inside phase, corner cutting phase and straightlinear cutting out phase. The90°corner cutting thickness calculation model ofmilling process is established through the discretization of cutting tool site. Thecorner of arbitrary angle (0°~180°) of the milling stage is divided on the abovebasis, and the arbitrary angle corner milling process model of the cuttingthickness is established, which lays foundation for the subsequent corner millingforce simulation.Secondly, the flat end mill corner milling forces simulation model isestablished. After the linear milling experiments of different cutting parameters,the tangential cutting force coefficient Ktc, the radial cutting force coefficientKrc, the axial cutting force coefficient Kac, the tangential blade force coefficientKte, the radial blade force coefficient Kre, the axial blade force coefficient Kaecan be obtained through linear regression for the Cr12MoV. The corner millingforce simulation model is established according to the milling force model ofdifferent milling conditions of the integral upper and lower bounds. Moreover, the flat end mill corner milling forces simulation software isdeveloped. Arbitrary angle corner machining process of milling force predictionis completed by the MATLAB software, and the software application interface isdeveloped by using the GUI module. After inputting the correspondingparameters according the prompt information, the user can quickly get themilling forces simulation curve under the current condition to guide the actualprocessing. Experiments shows the effectiveness of the corner milling forcesimulation model.Finally, the feed rate optimization is studied for the corner milling process.In order to optimize the mould corner milling, the feed speed sectionoptimization method is put forward based on the corner milling forces simulationmodel. The feed rate optimization of the mould corner milling is realized by theoffline processing of NC codes.