Research On Milling Force Perdition And Deformation Error Of Ruled Surface By Flank Milling

The complex ruled surface is widely used in the aerospace,automotive and other advanced industrial fields,and its processing level reflects the level of a country's advanced manufacturing.Flank milling is a typical processing technology with high efficiency,which is widely used in the machining of ruled surface parts.Because of the complex shape of the ruled surface,the milling force and the stiffness of the machine tool are constantly changing.At present,the traditional milling deformation research mainly focus on the finite element simulation analysis and the applied force was predicted by classical method,without consider the influence of the workpiece surface feature on the milling force and the overall stiffness of the machine tool.So it was proposed a milling force model and machine tool stiffness model based on workpiece surface feature in this paper,then combined the two-model to predict the deformation of arbitrary discrete points,which not only help us to recognize the error performance of the surface deformation,but also provide a theoretical basis for the control of flank milling deformation.The Chinese S shaped test specimen with variable curvature continuity,convexity concavity and other characteristic,can be used as a complex typical ruled surface,therefore we take flank milling of S specimen as an example,aims to propose a new model for predicting the deformation error of complex ruled surface.The main research work is as follows1.Based on the theory of classical milling,a general prediction model of milling force was established.Moreover,the key influencing parameters of the model were adjusted and optimized.Based on the principle of S curve acceleration and deceleration,the milling speed was calculated by the multi-constraints of machine performance,and the influence of different surface characteristics on the engagement angle and feed per tooth along cutter contact path was analyzed.2.The general stiffness model for the whole process system was obtained with consideration of the stiffness of the machine tool axes,the tool and the workpiece.The stiffness of the machine tool axis was obtained by means of the lumped parameter method.The stiffness of the tool and the workpiece was calculated by the finite element method.In addition,the variable stiffness model for the processing space of the machine tool was obtained by Jacobi matrix.Taking the S specimen as an example,the distribution law of the normal stiffness of the machine tool along the ruled surface under different processing positions was analyzed.3.By combining the model of milling force and the machine tool stiffness,the general prediction model of the deformation error of the ruled surface by flank milling was established.Taking the side milling S specimen as an example,the influence of the characteristics of the workpiece surface on milling deformation error was studied,and through the simulation model by changing the stiffness of different axis,we could get the change machining error compared with the initial state.Analysis of the influence of different types of machine tools and different cutting parameters on the milling deformation error,to provide some reference to the control of side milling deformation error,and the results were verified by experiments...