Instantaneous Cutting Behavior Of High Energy Efficiency Milling Cutter And Its Evaluation Method

High speed milling technology is widely used in aviation,aerospace,automobile and mould industries with its excellent efficient cutting performance.Achieving high energy efficiency of milling cutters meets the industry development topics of "energy efficiency and low carbon manufacturing" and has important practical significance.Considering the energy efficiency index in energy efficient in the milling cutter design,the cutting behavior of high speed face milling cutter with vibration is calculated,and a method of surface morphology simulation and transient cutting force of milling cutter is presented.Based on the relationship between cutting energy consumption and machined surface quality,the high efficiency milling cutter evaluation model is presented.In this paper,in the reference system of cutting motion of cutter tooth and the milling cutter coordinate system,the milling cutter cutting posture model and the cutter tooth position posture model under vibration condition are established.Using three-dimensional coordinate transformation method,the relationship among each coordinate system in the frame of reference is established,and then the position equation is established to solve any point on cutter tooth in the workpiece coordinate system.To characterize the cutting behavior of cutter tooth under vibration,equations of the motion trajectory of tool tip,the main cutting edge and auxiliary cutting edge are established on basing of the position equation of the milling cutter blade.According to the vibration characteristics of the milling cutter,the solution method of the instantaneous position angle of the cutter tooth is presented with a solution example to verify its feasibility.With two different machined methods of the up milling and down milling,the effective cutting times of each cutter tooth are solved.Combined with the solution equation of cutting behavior of cutter tooth under vibration,the solution equation of effective cutting behavior of cutter tooth is established and the high-speed milling surface topography Z-map model is built.The simulation method of machined surface topography of face milling cutter under the vibration is proposed and the simulation process and the simulation example are presented.Based on the simulation result of the machined surface morphology,the solution model of instantaneous cutting force of milling cutter is established and the solution method of the instantaneous cutting energy efficiency is given.Based on the instantaneous cutting energy consumption and the residual height of machined surface,the evaluation model of milling cutter energy efficiency is established,and then the instantaneous cutting behavior of the milling cutter is calculated.Therefore,the evaluation method of cutting efficiency of milling cutter is presented with an evaluation example.