Research On Surface Forming Of Non-ball Head Cutter Milling Parts Based On Real Cutting Edge Trajectory

CNC milling is a commonly used metal cutting machining in the machinery manufacturing industry,which has a wide range of processing,high processing efficiency advantages,so more and more widely used.In the study of milling process,the trajectory of the cutting edge of the milling cutter is simplified as a circular arc,and the simplified trajectory of the cutting edge of the milling cutter is equivalent to only considering the rotary motion of the cutter,without considering the feed motion of the cutter.When the milling cutter diameter is much larger than the tool feed in the milling process,the tool cutting edge trajectory is simplified into a circular line to study and analyze,the error generated is relatively small,can be ignored,but for most other milling process of this error can not be ignored.With the improvement of machining accuracy,the study will inevitably consider the coexistence of two kinds of motion.When considering the rotation and feed motion of the milling tool simultaneously,the real trajectory of the cutting edge of the tool should be considered,that is,the subcycloidal motion trajectory.In most of the studies on the surface topography of milling parts,the fan-shaped residues caused by discontinuous distribution of cutting edges are not considered.In this paper,the subcycloidal trajectory model of end milling tool was established by analyzing the true trajectory of cutting edges,and the sector residual on the side milling surface of end milling cutter was studied considering the true trajectory of discontinuous distributed cutting edges.(1)The parametric equations of cycloid and subcycloid are deduced and given,and the curvature and radius of cycloid and subcycloid are calculated according to the parametric equations.The curvature of the cutting edge trajectory in the forward and reverse milling is calculated and compared.(2)The mathematical model of the tool surface and the cutting edge of the end milling cutter were established.The simulation and comparison of the surface of the end milling cutter side milling part without considering the cutting edge and the surface of the side milling part considering the discontinuous distribution of the cutting edge were carried out.(3)The calculation formula of the height of the sector residue is derived by considering the real trajectory of the end milling cutter as the subcycloidal trajectory.In this paper,Z-MAP method was used to simulate the fan-shaped residues in the surface topography of the workpiece with discontinuous distribution of cutting edges.The variation of fan-shaped residues on the workpiece surface was observed by changing the cutter radius and the number of cutting edges of the end mill.Residual height calculation formula is derived using sector,calculated in the MATLAB software,by changing the end mill cutter radius size and endmill cutter cutting edge number,observe the change of surface residual height sector,and summarize the corresponding change rule,and puts forward the method to control the fan residue,the actual milling has certain positive meaning.