Multidisciplinary Design Optimization Of Milling Cutter Based On ISIGHT

In high-end and high-performance tool industry, China accounts for only about 10% of market share. Relatively backward production capacity leads to the import dependence of high-end tools in our country. Therefore, mastering advanced modern tool manufacturing technology, improving the degree of automation in design process, accelerating tool design process and achieving integrated optimization of tool design can get rid of tool import dependence and rapidly improve tool manufacturing level, which has become an important development direction.Milling cutters are widely used in cutting that can not only process plane, groove, step and so on, but also process thread, spline, gear and other shaped surfaces. End milling cutter is a kind of widely used milling cutter. Considering that different applications need different types of end milling cutters that have complex structure and diverse sizes, their design and optimization are very difficult.At present, the main methods of end milling cutter design and optimization are the traditional standardized tool design method and relatively advanced Computer-Aided Design (CAD). Both approaches require designers to repetitively modify tool parameters and analyze tool performance. Their automation degree is too low and they are short of the consideration of multiple-factor coupling effect on end milling cutter performance. To solve these problems, the paper studies multidisciplinary design and optimization of end milling cutters based on iSIGHT.Taking integral straight shank flat end milling cutter as the object, according to its grinding process on an ANCA five-axis CNC grinding machine, a precise mathematical model describing the process is established. The exact three-dimensional (3D) parametric model of the end milling cutter is also established in SolidWorks. Then, its modal and static finite element analyses are completed in Ansys. Finally, the process of 3D parametric modeling and finite element analysis is integrated in iSIGHT where the optimized structure of end milling cutter is calculated using iSIGHT embedded optimization algorithm.The study of the paper can realize the optimization of end milling cutter structure and parameters, improve its cutting performance, realize the automation of the entire design and optimization process and shorten its R&D cycle.