Development And Testing Of Chatter-Suppression Milling Tools Based On The Effect Of Process Damping

Milling chatter is easy to occur during the machining of thin-walled titanium alloy.In serious case,the processing quality of the workpiece is often deteriorated,the processing efficiency is limited and the production efficiency is reduced.Therefore,starting from the essence of milling chatter,based on process damping effect,this paper puts forward the design scheme of vibration suppression tools,which changes tooth spacing,helix angle or vibration elimination edge,and carries out numerical simulation verification and experimental verification.The main research contents of the paper are as follows:(1)The milling dynamic models of variable pitch milling tools and variable helix milling tools are established by considering the time delay effect.Then,the tooth spacing of the variable pitch tool is optimized.In addition,the influence of the tooth spacing,the reference helix angle and the equal difference of the helix angle between the adjacent cutter teeth on the milling stability of the titaniu m alloy thin-walled parts is analyzed with the numerical simulation.(2)Based on the research of variable pitch tools and variable helix-tools,the design of changing both tooth spacing and helix angle is proposed.The numerical simulation is used to analyze the vibration suppression effect of the tool changed tooth spacing and helix angle simultaneously.And then,the advantages of vibration suppression among variable pitch milling tools,variable helix milling tools and milling tools changed both tooth spacing and helix angle are compared.(3)Based on the process damping effect,the influence of the mesoscopic vibration eliminating edge formed by the chamfering of the tool rake face on the milling stability is anal yzed.And the reasonable effective length of the vibration eliminating edge and the length region of the vibration eliminating edge at different speeds are obtained.(4)According to the numerical simulation results,ten kinds length of the vibration eliminating edge are selected to make the end mills,and the milling experiments of titanium alloy thin-walled parts are carried out by using the cutters made.The acceleration signal is collected by LabVIEW SE,and the frequency domain results of acceleration are obtained through MATLAB Fourier transformation.Then,the milling stability of tools is analyzed based on acceleration spectrum,and the reliability of numerical simulation is verified.