Design And Optimization Of Ball End Mill For Titanium Blisk Flank Milling

Blisk is an important part of aeronautical engine, but its structure is complex and materials difficult to machine, which are key technical difficulties in cutting process. Blisk machining requirements are also gradually increase along with each passing day of aircraft engines, there is a low processing efficiency, short tool life and machining deformation in the cutting process, tool performance plays a crucial role for the above question. In this paper, disc/plunge/flank complex milling process have been proposed in the project, ball end mill is designed, analyzed and optimized for characteristics of flank milling.Firstly, ball end mill is designed for titanium blisk flank milling. The structure of blisk and flank milling process are analyzed, which provides the basis for the design and analysis of ball end mill. Tool is designed starting from cross-section line of ball end mill for flank milling, mathematical model of edge and undercuts curve tool is established. Parametric model of tool is established through the tool edge line mathematical model based on UG, which is the foundation for analyzing and optimizating tool.Secondly, the designed tool is analyzed and optimized by finite element method. Tool geometry parameters are analyzed by DEFORM-3D simulation to ensure cutting performance, tool angle is optimized based on cutting force. Tool intensity is analyized based on ANSYS software, stress and strain of tool is obtained to ensure the tool strength. Natural frequencies and mode shapes of tool are mastered by modal analysis, which ensures to avoid resonance the cutting process.There aren't no interferometric and excessive cutting in flank milling blisk through UG CAM simulation.Thirdly, designed and optimized ball end mill is manufactured. Tool material is preferred for titanium blisk. Tool grinding wheel and process are analyzed and optimized according to the tool structure and material. Grinded tool from edge, edge line, precision is detected, then passivation and coating process of tool is carried out, which is to extend tool life.Finally, experimental reserch of titanium flank milling is performed by using designed ball end mill. Cutting force is analyzed about flank milling parameters. Prediction model of cutting force is established based on the above experimental research, which is to provide a reference for cutting parameters optimization of flank milling titanium. Multi-objective optimization model of cutting parameters is established, cutting parameters are optimized combination of range analysis.Special ball end mill is designed for flank milling of titanium in this paper, and cutting parameters are optimized flank milling titanium, there is great significance for efficient and high-quality machining of titanium blisk...