Research On Cutting Force Of 3D Vibration-assisted Milling Of Structured Surfaces

The structural surface has some special functions such as hydrophobic drag reduction and lubrication due to the special texture of its surface.In the field of microstructure manufacturing,vibration-assisted machining(VAM)has been widely studied and applied since it was proposed to produce micro-structure surface quickly,conveniently and economically.For cutting technology,cutting force is an important parameter index,which can directly reflect the cutting characteristics of vibrationassisted milling,and the machining parameters and vibration parameters are the key factors affecting the cutting force.In order to explore the influence of different parameters on cutting force,this paper carried out three-dimensional(3D)vibration assisted milling structural surface machining based on 3D vibration assisted machining platform,and makes the following research:Firstly,a 3D vibration-assisted milling method for machining structural surface was proposed,and the tool-workpiece relative motion trajectory and cutting trajectory of blade were analyzed.Based on the principle of right-angle cutting,a theoretical model of cutting force under vibration machining of ball-end milling cutter was established by using the element method,and the influencing parameters of cutting force were determined,which provided theoretical support for later research.Secondly,the platform response displacements under different frequency voltages were measured by the vibration device displacement calibration experiment,and the relatively stable vibration parameters were determined by integrating the response curve results.The finite element model of 3D vibration-assisted milling process was established by using ABAQUS finite element software,and multi-group cutting simulation analysis was carried out by single factor method.By post-processing,the Mises stress pattern and cutting force waveform were obtained,and the effects of spindle speed,feed velocity,amplitude and vibration frequency on cutting force were obtained.Finally,according to the previous theory and simulation basis,the accuracy of the finite element model and the correctness of the simulation results were verified by 3D vibration assisted milling experiments.The surface structure of machined specimens was detected,and the surface topography and feed direction profile curves were obtained.The variation of cutting force waveform curves under different surface and contour sizes was analyzed,and the influence of cutting parameters and machining parameters on surface structure and cutting force was explained reasonably.At the same time,a large number of complex trajectory machining experiments were carried out to obtain the surface with complex structure,and a new cutting force cycle law was obtained,which provided an important reference for the follow-up research of 3D vibration assisted milling of structural surface.