Finite Element Analysis And Experimental Study On Helical Milling Of Titanium Alloy

In order to improve the ability of quick response and autonomous operation, the development trend of armored vehicle is lightweight. Because the titanium alloy material has the advantages of low density, high strength, good corrosion resistance, and it has been applied in aerospace field successfully, so it will be applied in the armored vehicle. Titanium alloy is a kind of material that is difficult to cut, especially the hole machining is more difficult, The hole machining of titanium alloy parts is still used in drilling process, because of the high axial force, poor surface machining quality and high processing cost, it is not suitable for the hole machining of titanium alloy parts. This paper mainly focuses on the processing technology of the latest titanium alloy helical milling.After the main technical parameters of the machine tool has satisfied the requirements, the main factors that determined the quality and efficiency of the cutting process was the tool(materials and structures) and cutting parameters(spindle speed, feed rate, axial cutting depth).This paper used theoretical analysis, simulation and experimental methods to study the influence caused by tool structure and cutting parameters on the physical phenomena(chip deformation, cutting force, cutting temperature) and surface roughness focusing on the helical milling process of the titanium alloy. This paper completed the structural design of the tool and the optimization of the cutting parameter, that provided a basis for the practical application in the production.The tool need to be designed according to the processing characteristics of titanium alloy and the characteristic of the helical milling.The finite element simulation of the machining process of the helical milling is carried out. The twodimensional cutting model is established to simulate the rake angle of the tool how to influence on cutting temperature and cutting force, the influence of tool helix angle on the cutting temperature and cutting force and the influence of cutting parameters on cutting force are obtained by using the 3D simulation model. In this process the whole revolution cycle curve characteristics of helical milling cutting force diagram is obtained by finite element simulation for the first time.The finite element simulation results are verified by the test method, and the simulation results are proved to be effective. The influence rules between the cutting force and cutting parameters were studied, the empirical formula of cutting parameters and cutting forces is established by orthogonal test and multiple linear regression. The cutting temperature of different cutting parameters was measured by infrared temperature measuring device to get the trend chart of the effects of spindle speed, feed speed and axial cutting depth on cutting temperature.Single factor method was used to study the influence of different cutting parameters on the surface roughness, the relationship between cutting parameters and surface roughness is established by the method of surface response. By combining genetic algorithm with Pareto method realized the optimization of cutting parameters(spindle speed, feed rate, axial cutting depth).