Cutting Force Theoretical Modeling And Finite Element Analysis In Plunge Milling Process

As a roughing and semi-finishing processing method,plunge milling can rapidly remove large quantity of material,and it's one of efficiency methods in milling.Rapid development of plunge milling has been very widely used in the aerospace,precision machinery,shipbuilding and mold manufacturing and other industries.In this paper,by taking Cr13 of scoop-type turbine stainless steel as experimental material,plunge milling process is studied.Firstly,the paper elaborates characteristics and working methods of plunging milling and analyzes generally research status and the shortcomings and deficiencies of the research process of plunging method.According to the mechanism of plunging method,the paper conducts the research of cutting force and cutter edge,and the rotation angle are broken down into micro-element,which wins the instantaneous milling force model and the average milling force model in plunge milling process.By MATLAB,the value of maximum milling force is calculated,which is the theoretical basis for experiments.Secondly,a brief introduction of the structure,library materials,processes and other modules of DEFOEM,for scoop-type turbine stainless steel work-piece material the choice of plunge milling cutter body and indexable insert material for Cr13 are conducted.Based on the setting of plunge milling's attributions and the drawing of special model,DEFOEM-3D simulation software is employed to simulate the process.After that,cutting force,cutting temperature and cutting tool stress etc.are obtained,and deformation and modal of the plunge cutter are acquired.Finally,the paper describes the experimental conditions and the experimental cases,ensures the experimental processing equipment and laboratory analytical methods.By considering the effects of milling vibration on milling thickness,the theory of milling force model is refined.By applied plunging experiment,three group experimental data is obtained,which lays the foundation for the test ofplunging theoretical model of milling force,achievement of simulating milling force by DEFORM-3D milling simulation,the establishment of theoretical model of milling force,and predication of cutting force in the process of milling force plunging.