Analytical Modeling Of Tool Wear In Side Milling Of Titanium Alloy

Titanium alloy(Ti6Al4V)for aerospace industry is widely used in the manufacturing of aerospace industry parts because of its low density,high specific strength,high temperature resistance and corrosion resistance.However,due to its low thermal conductivity,Ti6Al4V is a typical hard to machine material.Cemented carbide tools with excellent properties are widely used in the machining of Ti6Al4V.However,in the process of high-speed side milling Ti6Al4V,the periodic change of side milling temperature and milling force makes the carbide tool easy to wear,and the serious tool wear has a great impact on the workpiece surface processing quality and efficiency,so the main contents of this paper are as follows:First of all,in the initial stage of side milling titanium alloy with fla t end milling cutter,the temperature field of the rake face is analyzed and modeled without considering the tool wear,which is verified by the finite element method and experimental method.The model is based on the moving heat source method,and takes into account the time-varying characteristics of the heat source intensity and heat distribution ratio of the rake face and chip contact area as well as the rake angle of the cutter.The effects of side milling depth and speed on the heat distribution ratio and heat source intensity of the rake face and chip contact area are studied.Then,for the non initial stage of side milling titanium alloy with flat end milling cutter,considering the wear of the flank face,the temperature field of the wear zone of the flank face is analyzed and studied,which is verified by the experimental method.The model is based on the moving heat source method,and takes into account the time-varying characteristics of the heat intensity and heat distribution ratio of the heat source in the contact area of the front cutter face and chip,the contact area of the flank face and workpiece,and the non-contact loss heat source of the flank face and workpiece,as well as the rake angle of the cutter.The influence of side milling depth and speed on the heat distribution ratio and heat source intensity of the wear zone of flank face and the contact zone of workpiece were studied.At last,the wear process of titanium alloy flank milling with flat end milling cutter is studied by analytical modeling,and the wear analytical model of flank milling cutter based on wear mechanism is established,which is verified by experimental method.The model will further provide theoretical basis for the reasonable selection of tool geometric parameters.In this paper,the influence of the temperature of the flat end milling cutter on its wear during the side milling process of Ti6Al4V is studied,and the analytical modeling method of the temperature field of the flat end milling cutter is proposed.Finally,the analytical model of the wear width change rate of the flank face of the flat end milling cutter for Ti6Al4V machining is established.