Research On Geometric Modeling And Cutting Simulation Of Blade Milling Cutter

With the development of modern machining technology,as the representative of typical difficult machining parts of the free-form surface,the surface quality and accuracy of blade machining reflect the industrial development level of a country.In the process of machining free-form surfaces,five-axis and other multi-axis NC machine tools show excellent performance,so NC milling has become the preferred choice for machining free-form surfaces.In the research process of this subject,the carbide four edges chamfered end milling cutter are considered as the research object,the design,grinding,detection of milling cutter,and the cutting performance of milling cutter are considered as the main research content.Through high-speed milling aisi4340 alloy steel,the single factor test method and orthogonal test method are used to explore the influence of tool structural parameters and milling parameters on cutting performance,so as to improve the tool design theory.The specific research contents of this topic are as follows:1)Modeling,grinding of four edges chamfered end milling cutter,and detection of key structural parameters.According to the design principle of the milling cutter,the structural parameters of the cutter were designed.Aiming at the chamfered flank of the cutting edge at the key part of the end milling cutter,the grinding mathematical model of the chamfered edge was established.The grinding process analysis and grinding simulation of the four edges chamfered end milling cutter were carried out using the NUMROTO grinding software of ANCA FX7five-axis NC grinder,and the key structural parameters of the ground four edges chamfered end milling cutter was detected by using Zoller Smart Check 450 cutter tester.The test results show that the structural surface integrity of the end milling cutter is good: the end milling cutter has no crack,edge collapse,and edge notch the geometric angle error of the cutter is within ± 0.5 °and the dimensional accuracy error is within ± 0.025 mm.According to the cutter design theory,the grinding error is within a reasonable range and meets the requirements of processing conditions.2)Establishment of the milling simulation model and two-dimensional equivalent milling model of aisi4340 alloy steel based on DEFORM-3D.Using the NX12 0,a model of four edge chamfering end milling cutter with an equal helix angle was established.According to the motion principle and mode of the milling edge of the milling cutter,the workpiece geometric model based on hypocycloid was established;based on the modeling process flow of DEFORM-3D software,the milling simulation model of aisi4340 alloy steel was established.In order to improve the milling simulation efficiency,according to the equivalent uniform milling thickness model,a two-dimensional equivalent milling model was established at the same time.3)Milling performance analysis of finite element simulation based on DEFORM-3D.A single factor simulation experiment was designed.The influence of tool structure parameters and milling process parameters on milling performance,and the influence of different milling conditions on tool wear was analyzed based on the finite element simulation software DEFORM-3D.A 4-factor 3-level orthogonal experiment was designed.The range analysis method and variance analysis method were used to establish the prediction model of tool milling force and milling temperature.The weighted model was optimized through a multi-objective genetic algorithm.It is concluded that when the minimum milling force and milling heat are taken as the evaluation criteria,the optimal combined cutting speed v is 300 m /min and the tool rake angle ? is 11°,tool back angle ? is 7°,and the blunt circle radius of the tool r is 0.15 mm.4)Cutting force test and analysis.In order to verify the correctness of the DEFORM-3D finite element simulation model,a test platform was built to process the single factor simulation experiment designed above.The simulation was compare with the test value to verify the accuracy of the finite element milling model.Taking the radial rake angle,radial rake angle and spiral angle of milling cutter as the research object,the orthogonal test was designed.It is found that when the radial rake angle of the milling cutter ? is 9°,radial back angle ? is13 ° and helix angle ? is 35°,the milling force is the smallest,the simulation value of milling force is always less than the test value,and the maximum error is 10.77%.The research results show that the structural parameters of the milling cutter such as radial rake angle,radial clearance angle,helix angle,and the number of teeth of the milling cutter,as well as the milling process parameters such as the feed per tooth,spindle speed,axial depth of cut,and radial depth of cut,etc.The wear of the tool has an important impact on the cutting performance and processing efficiency.For different processing parts,designing special cutting tools can improve the processing quality and efficiency of the parts,thereby improving the design theory of the tool.