Analysis Of Physical Fields And Safety Margin Control Method Of High Speed Cutter

High speed machining technology is being widely applied to aerospaceindustry, automobile mold industry, medical device industry and so on. It hasshown a great many of advantages, but also exists the problem of safety andreliability on milling cutter. Especially for automobile hardened steel molds, ithas high hardness, complex groove, different hardness connection and manycorners, therefore, it often causes lots of difficulties for manufacturingenterprises. And the tool wear, breakage and fatigue fracture is prominent. Thisnot only influences the mold surface processing quality, but also more affected tothe cutting efficiency and processing cost. Consequently, the safety andreliability problems of cutting tools in the milling process of hardened steelurgently need to be resolved. Then, it will make a lot of sense to the hardenedsteel mold machining with high efficiency, high precision and high surfacequality. This paper is to evaluate and analyse the physical fields of high speedmilling cutter based on the high speed milling theory and high speed millinghardened steel experiment. The contents of this paper are as follows.On account of the characteristics of high speed milling hardened steel,establishing failure criterion of high speed milling cutter in accordance withstandard of ISO15641"Safety Requirements of High Speed Milling Cutter".According to the theory of safety margin, the physical field evaluation model ofmilling cutter is created. It can provide reference for the reliability judgement onhigh speed milling cutter.Through the model analysis, getting the influence of milling cutter overhangon the modal parameters of milling cutter, such as inherent frequency, stiffnessand damping. Through the thermal coupling field analysis, acquir ing theinfluence of cutting parameters and blade wear on stress fie ld and thermal fie ld. Through the analys is of impact stress and fatigue life, obtaining the influencingrule of cutting force and cutting vibration to impact breakage and fatigue life ofhigh speed milling cutter.On that basis, through safety and reliability simulation analysis of high speedmilling cutter in machining hardened steel part with general type surface,receiving the effects of hardness, cutting parameters, and the tool path onphysical characteristics. On that basis, combined with physical field evaluationmodel, this paper puts forward safety margin controlling method of high speedmilling cutter. That provides an effective method for safety judge and reliabilitycontrol of the milling cutter in the process of machining hardened steel mold.Finally, experimenting with process optimization on the punch, die of quenchhardening steel with3-D complex curved surface and different hardnessconnection by adopting the safety margin controlling method of high speedmilling cutter. The results of the experiments show that the method in this paperis feasible, and is applied in producing.