Milling Force Simulation And Stability Analysis Of Multi Hardness Hardened Steel Structure

Hardened steel has good hardenability and excellent wear resistance,and in order to meet the increasing demands of the complex requirements of cavity in different parts with different stresses the welding manufacturing mosaic of hardened steels with different hardness have been widely used in aerospace,cars and so on.Due to differences in material properties,the milling of the hardened steel mould structures is easy to be instable,and the milling chatter would increase the tool wear and reduce the surface quality and machining efficiency.Therefore,predict the hardness of hardened steel structure during milling milling force and milling stability analysis,can provide reference for the efficient milling of hardened steel mould,and it has an important scientific significance and application in engineering.This paper focuses on the structure of multi hardness hardened steel milling milling force and stability prediction etc using finite element analysis,dynamic modeling,modal parameter identification,stability analysis and experimental study.The main work can be concluded as follows:(1)By using ABAQUS the three-dimensional oblique cutting of the hardened steel has been simulated,and the distribution of the cutting force can be obtained.Then,it is to analyze the effect of different cutting speeds and cutting depths,and inclination angles on the cutting force.Finally,the numerical results have been verified by milling force tests and micro hardness tests,which can be used to explain the increase in welding cutting force correctly.(2)Based on the formation mechanism of regenerative chatter,the analytical model of dynamic milling force and the predictive model of milling stability are developed,and the corresponding coefficient of the milling force is obtained under the condition of different hardness of hardened steel balls using the milling test.While the modal and the associated parameters of the ball end milling cutter is obtained from the hammering method.(3)The stability lobe diagram is drawn based on the stabale prediction model,and the effect of the important parameters on the milling stability is analyzed,and the correctness of the stability lobe diagram is verified by the stability tests as well.In this paper,the milling force and stability of the hardened steel welding with different hardness is discussed both numerically and experimentally,and it can provide theoretical guidance and basis for the selection of machining parameters for high speed milling of hardened steel with different hardness.