The Structural Design And Process Research Of Rifling Processing Cutter System

With the continuous development of smart manufacturing technology,manufacturing large calibre gun with long range and high hit rate has become the general trend of industry development.Rifling as one of the important links in the process of artillery trial production,which has an extremely important impact on the life of calibre barrel and precision of hitting the target.Among,the broach is one of the main tools for processing the body rifling,which directly affects the surface quality and processing efficiency of the inner wall of the body pipe.Therefore,it is necessary to study the damping of the tool system and the optimization of the geometric parameters of the tool during the rifling process.Based on the technology research and the finite element analysis,the article designs a"pulling/boring"combined tool system for specific rifling machining.Analyzes and verifies the damping effect of its internal damping groove.At the same time,the influence rules of broaching force and residual stress generated when using different tool geometric parameters to process rifling was studied,the tool geometric parameters were optimized.As a result,the rifled surface quality and efficiency could improve significantly.As follows,there are the main researches:（1）The paper studies the function of increasing the working angle of the boring tool on the basis of the broach structure and introduces the relationship between the main geometric parameters and the working angles of the tool.Furthermore,according to the total structure of broach and boring cutter combination cutting tool system.it estalishes a cutting head three-dimensional model according to the working principal of broach and boring cutter combination cutting tool in the software of Catia.（2）This paper introduces the common vibration types and the causes of vibration in the machining process.Based on the principle of fluid damping,a double-layer boring bar structure with a vibration damping groove on the outer surface of the inner boring bar is designed.（3）The paper not only establishes a hydrodynamic and a dynamic model of a double-layer boring bar structure with internal boring bar vibration damping groove,but also builds a fluid-Mechanics simulation and dynamics simulation using finite element software Fluent and Simulink.Based on this,the design of the vibration reduction groove structure is improved,and the vibration reduction of the boring bar is studied from three aspects:the size parameters of the vibration reduction groove on the outer surface of the inner boring bar,the position and number of the vibration reduction grooves and the structure distribution of the vibration reduction grooves.（4）The geometrical angle of the cutting head of the cutting tool system is optimized.The cutting head front angle,back angle,left side deflection angle and right side deflection angle are selected as test factors,and the orthogonal test method is used to design the test plan.In the simulation,Catia software is used to establish 29 sets of different cutter head geometric models with different rake angles,rake angles,left side deflection angles,and right side deflection angles.then a three-dimensional model of tube processing was established by the finite element analysis software ABAQUS.The rifling machining simulation of 29 sets of different tool geometric angle combination models is established to obtain the broaching force,torque,broaching temperature,and residual stress on the surface of the body tube under the 29 sets of different tool geometric angle combinations.（5）Based on the surface response method,a prediction model of broaching force and surface residual stress is established and the geometric angle of the tool is optimized.Based on the Box-Behnken test design（BBD）principle,a four-factor and four-level response surface experiment is designed to analyze the entire model and analyze the significance and validity of the model.Besides,it bulids a second-order response surface prediction model for the broaching force and the residual stress on the surface of the body tube.According to the model,the action laws of each cutter geometric angle on R₁ and R₂ are analyzed,and the combination of the cutter head geometric angles with a test result of 91.4%expectation is obtained,which provides the certain reference for the actual production.