Research On Integrated Simulation And Optimization Of Ball-end Milling Cutter Milling Titanium Alloy Considering Residual Stress

Titanium alloy is widely used in aviation,aerospace,energy,biomedical and other fields because of its high specific strength,high creep corrosion resistance and high wear resistance.Milling of titanium alloy is a process of intermittent cutting.Because of the complex relationship between tool and work and the tendency of unstable state of workpiece in the process of cutting in and out,the size of tool geometry parameters and cutting parameters will affect chip formation,tool life and surface quality.In view of the above milling process characteristics and the characteristics of TC4 titanium alloy materials,through theoretical analysis,simulation simulation,scientific experiment and optimization technology,the integrated simulation optimization research of cutting simulation and optimization technology is carried out,that is,the integrated simulation optimization of parametric design(UG design),finite element simulation(ABAQUS simulation)and integrated optimization(i SIGHT optimization)Research.In this paper,the ball end milling cutter milling TC4 titanium alloy as the research object,the specific research is as follows:Firstly,the mathematical model of the space edge line of the ball end milling cutter is established.Under the environment of UG,based on the method of feature variable setting,the three-dimensional solid parametric model of the ball end milling cutter is obtained.Based on the MATLAB modeling module,the correctness of the mathematical model is verified.Based on Numroto plus(R)simulation platform,the grinding simulation process planning of ball end milling cutter is established,and the ball end milling cutter is prepared by saacke-uwii tool grinder,which lays the foundation for the experimental research of titanium alloy milling.Secondly,the three-dimensional finite element model of milling process is established by using the key technology of finite element cutting simulation and ABAQUS finite element software to simulate the distribution trend of milling force,milling temperature,Mises equivalent stress and residual stress layer at different times.Thirdly,based on vdl-1000 e vertical milling center,the ball end milling cutter prepared in Chapter 2 is used to carry out the experimental research of titanium alloy milling and residual stress test.The experimental data is compared with the simulation data to verify the accuracy of the three-dimensional milling finite element model of titanium alloy.Finally,based on the integrated optimization environment of i SIGHT software,the integrated simulation and optimization platform for the geometric parameters of ball end milling cutter and the integrated simulation and optimization platform for the cutting parameters considering the residual stress are built,the optimization objectives are determined,the software execution and interaction are carried out,the optimization strategies are proposed,and the design variables are optimized.In this paper,the cutting performance of the tool is combined with the machining quality of the workpiece.The optimized geometric parameters of the tool are the effective means to improve the cutting performance of the tool.The optimized cutting parameters are the optional basis to improve the machining efficiency.It is of great scientific significance to provide a scheme for the milling of titanium alloy workpiece.