Simulation Of Cutting Force In Helical Milling Process And Its Application Study On The Influence Rule Of Machining Quality

The traditional hole-making technology applied in aerospace field needs to meet a series of complicated processes such as drilling,expanding and twisting to ensure the machining quality and precision level,which is difficult to guarantee the quality and inefficient.Therefore,the helical milling technology with axial feed along the spiral line is produced,which has the advantages of small cutting force,low temperature and few burrs on the workpiece surface,thus solving this problem well.The research topic of this subject is the research of cutting force in helical milling process and its influence on machining quality.Among them,the research of cutting force in helical milling process is mainly from micro to macro,that is,from cutting process to drilling and then to finite element simulation process of helical milling.The machining quality is mainly evaluated by the shape of undeformed chips.The main research contents and conclusions of this paper are as follows:(1)The introduction introduces the helical milling technology,the background of cutting and their research status.By comparison,it is decided to use the finite element software ABAQUS to simulate cutting,drilling and helical milling.(2)In foundation of finite element simulation model,the application fields and basic ideas of finite element simulation theory are introduced,and the influencing factors of cutting force are pointed out,which are regarded as simulation independent variables,and the simulation results of cutting force and chip morphology are regarded as dependent variables.Finally,the most important constitutive equation,chip separation criterion,mesh generation method and friction coefficient in the simulation are put forward and explained respectively.(3)The finite element method of cutting includes orthogonal cutting simulation and oblique cutting simulation.The effects of cutting speed,chip thickness,tool rake angle,tool relief angle,friction factor,tool fillet edge radius and tool chamfer edge radius on cutting force and chip morphology are analyzed in orthogonal cutting simulation.The influence of oblique angle on cutting force and chip morphology is analyzed by oblique cutting simulation.(4)In the aspect of finite element simulation of machining hole with end milling cutter,the finite element simulation of drilling hole with end milling cutter and the finite element simulation of helical milling with end milling cutter are made.First,the end mills are imported into ABAQUS,and then assembled with workpieces,meshed,and so on.The difference is that the drilling simulation module studies the influence of spindle speed and axial feed on cutting force and chip morphology.The simulation module of helical milling studies the influence of spindle speed and eccentricity on cutting force and chip morphology.(5)Finally,the paper is summarized.In orthogonal cutting simulation,the cutting speed with minimum cutting force is 30m/min,chip thickness is 0.1 mm,tool rake angle is 16°,tool rake angle is 14°,friction coefficient is 0.15,tool fillet edge radius is 0.01°,and tool chamfer edge radius is 0.01°.In oblique cutting simulation,the oblique angle is 10°.In drilling simulation,when the cutting force is minimum,the spindle speed is 225 rad/s and the axial feed speed is 0.3 mm/s.In the simulation of helical milling,the spindle speed is 100 rad/s and the eccentricity is 2 mm when the cutting force reaches the minimum value.