Research On Dynamic Milling Force Of High Energy Efficiency Milling Cutter Under Vibration

High energy efficiency milling cutter is widely used in high-end fields such as the aerospace industry for its high milling performance.In the process of milling,the dynamic change of the milling force of the milling cutter directly affects the milling stability,causes the tool wear and the surface quality deterioration.It is of great significance to study the dynamic characteristics of milling force and establish the correct dynamic milling force model of milling cutter for stable control of milling process and improvement of machining surface quality.In this paper,with the national natural science fund project "Multi-scale coupling mechanism of nonlinear friction dynamics wear of high energy efficiency milling cutter(51875145)",aiming at the effective control of dynamic milling force of high-efficiency milling cutter,the dynamic characteristics and control methods of milling force of milling cutter with vibration action are studied in combination with the example of high-efficiency milling.In view of the fact that the dynamic characteristics of the milling force of the high-energy milling cutter have been neglected in the existing res earch,which is the result of the joint action of the two mechanisms of the cutter error distribution and the milling vibration,the high-energy milling experiment is carried out.From the perspective of energy,the calculation method of the instantaneous milling volume of the milling cutter under the action of the cutter error is proposed,and the influence of the cutter error and its distribution on the instantaneous milling volume of the milling cutter is revealed According to the experimental results of milling vibration and milling force,the construction method of instantaneous milling volume,milling vibration and milling force behavior sequence of milling cutter is put forward,and the correlation characteristics of cutter error distribution,milling vibration and milling force are revealed;and the experimental scheme of changing cutter speed and cutter error distribution is adopted,The influence of the cutter tooth error and the milling vibration on the milling force of the cutter is revealed.The results show that the change of dynamic milling force characteristics of milling cutter is the result of the joint action of cutter error distribution and milling vibration.The above method can effectively reveal the change of milling force characteristics of milling cutter under the joint action of multiple factors,and provide the basis for the construction of dynamic milling force model of milling cutter.According to the influence of milling vibration on the instantaneous milling contact relationship between milling cutter and workpiece,the instantaneous milling posture of milling cutter and its teeth,the instantaneous milling layer thickness of milling micro element and the calculation method of instantaneous milling boundary of cutter teeth are put forward,and the change characteristics of instantaneous milling behavior of milling cutter teeth are revealed;the distribution state of instantaneous milling force of cutter teeth is characterized by micro element method,and the instantaneous milling force of cutter teeth is established The model reveals the changing characteristics of the instantaneous milling force of the cutter;constructs the instantaneous milling force system of the multi tooth milling of the milling cutter,proposes the solution method of the position vector and the force vector relation variable of the instantaneous milling force of the adjacent cutter,reveals the dynamic characteristics of the instantaneous milling force relationship of the adjacent cutter;verifies the dynamic characteristics and response characteristics of the milling force of the milling cutter through the milling experiment.The results show that the distribution of cutter tooth error and the change of milling vibration to the instantaneous milling behavior of milling cutter and its cutter tooth cause the corresponding change of the distribution state of cutter tooth instantaneous milling force and the change characteristics of the relationship between the instantaneous milling forces of adjacent cutter teeth,thus changing the dynamic characteristics of the milling forces of milling cutter.Using the above models and methods,the milling vibration,the structure parameters of milling cutter and the milling parameters can be identified The influence mechanism of dynamic milling force of milling cutter.Based on the dynamic milling force model of the milling cutter,the design variables of the milling force of the milling cutter are separated out,the process characteristic variables,the error distribution of the cutter teeth and the influence of the milling vibration on the milling force of the milling cutter are analyzed,and the dynamic milling force simulation scheme of the milling cutter is designed by using the response surface method,and the milling force relationship between the cutter teeth,the milling force of the milling cutter,the ideal and the actual milling are constructed The relation degree of cutter milling force and the response surface model of dynamic characteristics of cutter milling force.According to the results of response surface model variance analysis,combined with the dynamic milling force response surface of milling cutter,this paper analyzes the significant level of the influence of process characteristic variables,milling vibration and cutter tooth error distribution on the milling force size and dynamic characteristics of milling cutter,and reveals the influence characteristics of the interaction between the above design variables,which provides a basis for the control of dynamic milling force of milling cutter.According to the significant analysis results of the influence factors of the dynamic milling force of the milling cutter,the control variables of the dynamic milling force of the milling cutter are separated out.Taking the milling efficiency as the constraint condition,the dynamic milling force and the milling efficiency of the milling cutter as the control objectives,the control method of the dynamic milling force of the milling cutter is proposed in combination wi th the control sequence of the milling force of the cutter,the milling force relationship between the cutter teeth,the milling force size of the milling cutter and its dynamic characteristics.Taking the average value and extreme value of the curve of milling force and milling power as the characteristic variables,the evaluation method of milling force and milling energy efficiency of milling cutter is proposed,and the dynamic milling force control method of milling cutter is verified by two groups of milling examples.The results show that this method can effectively control the dynamic milling force of milling cutter.