Researching The Biomimetic Micro Texture Effect On Two-flute Ball-end Mill Cutting Performance

Two-flute ball-end mill was widely used for milling complex geometric surfaces.During milling process,two-flute ball-end mill was extremely subjected chip adhesion,consequently causes abrasion and decreases machined surface quality.Some organism's non-smooth microstructure surface plays considerable significant role in anti-adhesion and wear-resistance function.Based on bionics knowledge,the micro texture type impact on tool cutting performance and mechanism was investigated.Fabricating different width of biomimetic micro texture on the two-flute ball-end mill rake face to study its cutting performance and milling 6061 aluminum alloy surface quality.In order to provide technical guidance for improving two-flute ball-end mill cutting performance as well as milling surface quality,the machine learning of support vector regression was adopted to model and numerical analyze.The detailed research content is summarized as follows:(1)The metal cutting industry confronts problems were analyzed,especially aiming at tool extremely occur adhesion failure during 6061 aluminum alloy milling process.Meanwhile,biomimetic micro texture lack of research in milling tool and machined surface quality also was analyzed.So that proposing study the cutting performance of micro texture morphology and micro-textured ball-end mill.Based on metal cutting 2D shear plane model numerical simulation,according to comparing numerical results of the non-texture,crater,rectangular groove and trapezoidal groove tool,the best type of micro-textured tool was trapezoidal groove tool.(2)By scanning electron microscopy and cutting force of mean and maximum value,amplitude-frequency and wavelet decomposition,the trapezoidal micro texture width influence two-flute ball-end mill cutting performance such as anti-friction,milling stability,wear,anti-adhesion and cutting edge strength was studied.By 3D roughness parameter,fractal dimension and surface morphology,its milling 6061 aluminum alloy surface quality was analyzed.The results shown that the 70?m width micro-textured ball-end mill were the best via comparison others ball-end mill of anti-friction,milling stability,tool wear,anti-adhesion and surface quality.The micro texture width too large would cause unstable milling and worsen workpiece surface finish.However,all micro-textured two-flute ball-end mill can certain extent improve the fineness degree of workpiece surface texture.(3)Based on orthogonal milling experiment,by the machine learning of support vector regression,the micro-textured ball-end mill cutting force F and surface roughness S_a was modeled.The confidence interval of optimal micro texture width was analyzed via Bootstrap sampling method.The relationship surface map between machining parameters and combined cutting force F as well as surface roughness S_awas given in different width of micro-textured ball-end mill.The results shown that the micro texture width influences two-flute ball end mill response relationship between processing parameters and cutting performance.The micro texture width confidence intervals between 58.58?m and 83.85?m is best for designing micro-textured ball end mill.Overall,during dry milling 6061 aluminum alloy,the cutting performance and milling surface quality of two-flute ball-end mill could be significantly improved,if its rake face was designed into biomimetic micro texture form.Relevant theoretical guidance and methods proposed in this research can prompt the application and development of 6061 aluminum alloy process industries in aerospace,automotive,railway,consumer electronics and so on.