Research On Structure Optimization Design Of End Mill For High Efficiency Milling Nickel Base Superalloy

Nickel-based superalloy materials are often widely used in the manufacture of hot-end components such as aerospace engines and gas turbines due to their excellent thermal stability.Due to their low thermal conductivity and large friction coefficients,the difficulty of its machining increases and higher requirements are placed on machining tools.For the cutting of nickel-based superalloys,although some new material tools can improve the cutting performance,considering the economy and applicability,coated carbide tools are still the most suitable cutting tools.In the case of a certain tool material,in order to obtain more excellent cutting performance,it is necessary to optimize the design of the tool structure.This paper focuses on the side milling of nickel-based superalloy GH4169,mainly from the optimization of the tool geometry parameters,and at the same time,the optimization of milling parameters is studied.In order to establish a precise entity model of the end mill,according to the grinding process of the end mill spiral groove,the mathematical analysis model of the end mill spiral groove was established based on the curve enveloping principle,and the established model was verified in MATLAB.The problem of forward modeling and reverse modeling of the spiral groove of the end mill is studied,and the simulation modeling of the spiral groove of the end mill is realized by using 3D modeling software,the fast forward solid modeling of spiral groove of end mill is realized by defining the shape parameters and position parameters of grinding wheel.By analyzing the relationship between the grinding wheel installation position and the groove parameters,the iterative method is used to solve the installation position of the grinding wheel in reverse when the shape parameters of the grinding wheel and the spiral groove design parameters are known,and an example is given to verify that the spiral groove characteristics of end mill meet the accuracy requirements.On this basis,the side edge and end edge features of the end mill are added to obtain a complete threedimensional solid model of the end mill.The smooth surface of the model can be used for finite element simulation.The key technology of metal cutting finite element simulation is described,a threedimensional finite element simulation model for milling nickel-based superalloys is established,and the stress cloud diagram of the workpiece,the temperature cloud diagram of the end mill,and the milling force output curve are obtained.Designed a milling experiment to verify the accuracy of the simulation model.In order to reduce the error between the simulation and the experiment,the end milling cutter used in the experiment was reversely reconstructed,and the reconstructed tool was used for milling simulation.The results show that the established simulation model can predict the milling force generated during the milling process well.Using the established milling simulation model,under the condition of unchanged milling parameters,end milling cutters with different rake angles,relief angles,and helix angles are used for milling simulation experiments.Using cutting force and cutting temperature as evaluation criteria,single-factor optimization of tool geometric parameters is performed,and a suitable range of tool geometric parameters is optimized.Orthogonal test is used to analyze the range of tool geometry parameters as a whole,and the suitable tool geometry parameters are optimized.On this basis,for high-speed and large axial depth of cut,the natural frequency and deformation displacement of the first-order mode are used as evaluation criteria to perform modal analysis on end mills with different tooth angles,and unequal teeth are added to the end mill the characteristics of the angle.Orthogonal experiments were designed,and the optimized end mills were used to perform milling simulation experiments under different milling parameters.The cutting force and cutting temperature obtained from the experiment were analyzed by range,and the influence of cutting force and cutting temperature was comprehensively considered to obtain the best results,excellent milling parameters.