The Optimization Of Milling Parameters Based On PSO Algorithm And Simulation Research

Ball-end cutter has the characteristics of high efficiency,high precision and flexible cutting,which is widely used in curved surface milling process of aerospace,machinery,automotive,mold and so on.In the manufacturing industry,mold is an indispensable tool for complex components.For many molds have complex curved surface,the curved surface machining technology has became the key factor to the development of precision mold due to its difficulty for traditional processing technology.Die steel with high hardness,strength,wear resistance,stability and other mechanical properties,are widely used in mold manufacturing industry.Because of its poor cutting performance,it seriously restricts the precision development of mold.In this thesis,the process experiment,parameters optimization and 3D simulation of milling die steel with ball-end cutter are investigated.In the aspect of milling die steel SKD61,the experiment results of curved surface milling with ball-end cutter are analyzed,and found that the milling force on the first cutting edge is different on the second cutting edge in a milling cycle.The relationship between milling parameters and milling forces was analyzed by range and effect analysis,and respectively obtained theoretical value for milling force F_x,F_y,F_z under the optimal parameters by effect Calculating.In the aspect of milling force prediction and parameters optimization,the standard particle swarm optimization algorithm was introduced,and processed optimization analysis of milling parameters,respectively obtained prediction model of milling force F_x,F_y,F_z,F_xyz.The milling parameters are optimized with the processing efficiency,the maching cost and the tool life as the optimization objective,and analyzing optimization results,found that taking processing time and manufacturing cost as optimization goal,the shortening of processing time and the reduction of cost is at the cost of reduction of tool life.The result of multi-objective optimization is more suitable for practical maching.In the aspect of 3D simulation with using ball-end cutter to mill curved surface,the simulation results were analyzed,and found that the chip of SKD61 is not continuous in the cutting process,easily broken;At the initial stage o f milling,the cutting edge was affected by axial impact,and the milling force is higher than the stable milling stage;Stress simulation results showed that the influence of different process parameters on stress is different,and the effects of feed per tooth is the key.The research results in this thesis can help to enrich the milling theory of die steel,and can provide theoretical guidance for SKD61 processing.