Surface Morphology Distribution Characteristics And Simulation Method Of High Efficiency Milling

In the milling process,due to the influence of milling vibration and cutter tooth error,there are differences in the shape and structure of the machined surface formed at different positions of the machined surface.The existing characterization methods of machined surface morphology can not completely reflect the characteristics of machined surface morphology and structure,and can not reveal the distribution characteristics and formation process of machined surface morphology.Based on the national natural science fund project "Multi-scale coupling mechanism of nonlinear friction dynamics wear of high energy efficiency milling cutter(51875145)",The machined surface is divided into several parts,and the morphology unit structure of the machined surface is studied.The relationship model of milling cutter and its cutting movement under the influence of milling vibration is established,and the method of solving the machined surface topography element is proposed.The influence characteristics of milling cutter error,cutting parameters and milling vibration on the machined surface topography distribution are analyzed,which provides theoretical basis for the process control method.Firstly,the experiment of milling surface morphology of end milling cutter is carried out,and the control variables are extracted.The method of measuring the cutter tooth error is proposed,and the distribution sequence of cutter tooth error is constructed.The acceleratio n signals of milling vibration obtained from experiments are extracted to characterize the characteristics of milling vibration behavior.Detect the machined surface,identify and extract the contour feature points between the peak height and valley bottom of the machined surface,take the structure between the adjacent peak height as the machined surface morphology unit,use its contour feature points,use high-order polynomial to construct the machined surface morphology contour surface,and characterize the machined surface morphology.According to the relationship between the cutting motion of the milling cutter and its teeth with respect to the workpiece under the action of vibration,a method for calculating the instantaneous cutting position and attit ude of the milling cutter and its teeth is proposed,and the influence of the milling vibration on the instantaneous cutting behavior of the milling cutter and its teeth is revealed.In this paper,the micro element method is used to divide the milling mic ro element,to solve the movement trace of any point of the cutting edge,to extract the feature points between the movement traces of the adjacent cutter teeth,to reconstruct the profile surface of the machined surface,and to verify the experiment,to reveal the influence of milling method,cutting parameters,cutter tooth error and milling vibration on the distribution characteristics of the machined surface.By using the orthogonal analysis method and the simulation method of machining surface morpholo gy,the distribution of milling cutter tooth error,cutting parameters and the machined surface morphology under the influence of milling vibration are analyzed.The influence of milling cutter tooth error,cutting parameters and milling vibration on the d istribution of machined surface morphology is revealed,which provides the basis for controlling the distribution of machined surface morphology.According to the results of orthogonal analysis,the aim of the design is the uniformity of the surface topography distribution,the characteristic parameters of the surface profile equation of the surface topography are the design variables,the cutter tooth error and the cutting parameters are the constraints,and the influence of the cutter tooth error,the cutting parameters and the milling vibration on the surface topography distribution is analyzed Consistent design method.This paper proposes a method to evaluate the uniformity of surface morphology distribution in milling.Through milling experiments,an improved gray correlation analysis algorithm is used to verify the accuracy of the process design method for the uniformity of surface morphology distribution.