Research On The Method Of Instantaneous Cutting Thickness In Five-axis Milling With Ball End Milling

Five-axis milling is widely used in aerospace,rail transit,automobile mould and other high-end manufacturing industries due to its good processing capability of complex surface.However,in the process of five-axis milling,the changing cutting contact area of "cutter" leads to complex mechanical behavior,which is easy to produce machining defects such as chatter,deformation and rapid wear of the cutter,which restricts the improvement of machining efficiency and quality of five-axis milling In metal processing,cutting force is a key factor affecting cutter-workpiece vibration,chatter,cutting temperature,tool failure,workpiece size accuracy and surface roughness.At present,the cutting force mechanical model based on cutting principle and test method is widely used,the model consider cutting force as the coefficient and cutting depth and cutting width of the product,including the coefficient and cutting width of the research has made some progress,but analytical method and z-map discrete method are mainly used in the process of calculating instantaneous cutting thickness in five-axis milling,there are some bottleneck problems,such as poor robustness and low efficiency.Therefore,the instantaneous cutting thickness solution method based on Boolean operation of solid model is proposed.The specific research content of the paper is as follows:1.Based on the principle of differential geometry,a mathematical model is established for the curve of the lead helical blade of the ball-end milling cutter.Meanwhile,a three-dimensional solid model of the ball-end milling cutter is built based on the structural parameters such as the cutter radius and spiral Angle,as well as the Siemens NX software.2.Based on the principle of five-axis milling and the Boolean operation method based on solid modeling technology,the surface model of five-axis milling workpiece with ball end milling cutter and the cutting thickness solving model are established.The discretization method of ball end milling cutter blade is studied.3.Based on traditional instantaneous cutting thickness model and milling force test results,the accuracy of the established model is compared and analyzed.The results show that the instantaneous cutting thickness of five-axis milling can be obtained effectively based on the Boolean algorithm.4.In this paper,the instantaneous cutting thickness of different tool edge line shape under different tool position posture is studied,and the changing rule of instantaneous cutting thickness with tool angle is compared to optimize the shape of tool edge line.