成形槽技术在高刚性整体硬质合金立铣刀开发中的应用
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摘要
针对淬硬钢铣削时易产生高频振动以及刀具剧烈磨损导致耐用度低等问题,基于成形槽技术开发出芯部直径与铣刀直径比值达0.7的高刚性立铣刀,推导了螺旋槽径向截面形状的数学模型。进行了切削仿真和静力学仿真,仿真结果表明:较对比刀具,高刚性立铣刀平均切削力更大,切削温度和容排屑性能相差无几,刀具变形量更小。最后开展了切削实验验证研究,研究结果表明:较对比刀具,高刚性立铣刀加工零件表面粗糙度值由0.30μm下降到0.16μm,让刀量由0.18 mm减小到0.08 mm,刀具耐用度则由35 min提高到58 min,体现了高刚性立铣刀的性能优势。
Targeted at problems that high-frequency vibration in milling hardened steels and the low durability caused by sharp wearing of cutting tools, a high rigidity end mill was developed at 0.7 ratio between web thickness diameter and end mill diameter based on profiled groove technology. The mathematical models with radial section shape of spiral flutes were derived, cutting simulations and statics simulations were carried out. The results show that compared with cutting tools, high rigidity end mill has relatively larger average cutting forces, but similar cutting temperature, chip tolerance and removal performance and also small deflection. According to results of cutting experiments compared with cutting tools, the surface roughness values of machined parts of high rigidity end mill decline from 0.30 to 0.16 μm, and relieving amount deflection from 0.18 mm to 0.08 mm and the durability of cutting tools increases from 35 minutes to 58 minutes that embodies performance advantages of high rigidity end mills.
Targeted at problems that high-frequency vibration in milling hardened steels and the low durability caused by sharp wearing of cutting tools, a high rigidity end mill was developed at 0.7 ratio between web thickness diameter and end mill diameter based on profiled groove technology. The mathematical models with radial section shape of spiral flutes were derived, cutting simulations and statics simulations were carried out. The results show that compared with cutting tools, high rigidity end mill has relatively larger average cutting forces, but similar cutting temperature, chip tolerance and removal performance and also small deflection. According to results of cutting experiments compared with cutting tools, the surface roughness values of machined parts of high rigidity end mill decline from 0.30 to 0.16 μm, and relieving amount deflection from 0.18 mm to 0.08 mm and the durability of cutting tools increases from 35 minutes to 58 minutes that embodies performance advantages of high rigidity end mills.
引文
[1] 全燕鸣,王成勇,林金萍.高速铣削淬硬模具钢的工艺性与经济性研究[J].工具技术,2003,37(12):6-9.QUAN Yanming,WANG Chenyong,LIN Jinping.Study on Processing Property and Economical Efficiency for High-speed Machining of Hardened Steel[J].Tool Engineering,2003,37(12):6-9.
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[4] 苗淼.基于钛合金三维铣削仿真的立铣刀设计参数优化[J].制造技术与机床,2016(1):57-61.MIAO Miao.Optimization of Design Parameter of End Mill Based on Simulation for Three-dimensional Milling Process of Titanium Alloy[J].Design and Rasearch,2016(1):57-61.
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[8] 程剑兵.钨钴类超细硬质合金刀具及其切削性能研究[D].北京:北京理工大学,2015.CHENG Jianbing.Research on Cutting Performance of WC-Co Ultrafine Cemented Carbide Cutting Tools[D].Beijing:Beijing Institute of Technology,2015.
[9] 陈颢,羊建高,王宝健,等.硬质合金刀具涂层技术现状及展望[J].硬质合金,2009,26(1):54-58.CHEN Hao,YANG Jiangao,WANG Baojian,et al.Research Status and Expectation on the Coating Techniques of Cemented Carbide Cutting Tool.[J].Cemented Carbide,2009,26(1):54-58.
[10] 彭中伟.槽铣刀螺旋槽参数优化及高速刀柄动平衡的研究[D].哈尔滨:哈尔滨理工大学,2012.PENG Zhongwei.Rasearch on Slotter Chip-hold Gloove Optimization and Handle of High-speed Dynamic Balance[D].Harbin:Harbin University of Science and Technoloy,2012.
[11] 倪高明,孙振梅,左小陈,等.具有双圆弧槽型的立铣刀:中国,CN102303158A[P].2012-01-04.NI Gaoming,SUN Zhenmei,ZUO Xiaochen et al.Groove Type End Mill with Double Arcs:China,CN102303158A[P].2012-01-04.
[12] 刘朋和.钛合金薄壁件铣削动力学特征及表面质量研究[D].沈阳:沈阳理工大学,2015.LIU Penghe.Study on the Milling Dynamic Characteristics and the Surface Quality of Titanium Alloy Thin-walled Parts[D].Shenyang:Shenyang Ligong University,2015.
[13] 王素玉,赵军,艾兴,等.高速切削表面粗糙度理论研究综述[J].机械工程师,2004(10):3-6.WANG Suyu,ZHAO Jun,AI Xing,et al.Theoretical Research of Surface Roughness for HSM[J].Mechanical Engineer,2004(10):3-6.
[2] 王成勇,秦哲,吴世雄.淬硬钢模具的高速铣削加工[J].模具制造,2009,9(4):74-78.WANG Chengyong,QIN Zhe,WU Shixiong.High Speed Milling of Hardened Steel for Die&Mold[J].Die & Mould Manufacture,2009,9(4):74-78.
[3] 何理论.微细铣刀的失效分析与设计理论研究[D].北京:北京理工大学,2015.HE Lilun.Research on Failure Analysis and Design Theory for Micro End Mill[D].Bejing:Bejing Institute of Technology,2015.
[4] 苗淼.基于钛合金三维铣削仿真的立铣刀设计参数优化[J].制造技术与机床,2016(1):57-61.MIAO Miao.Optimization of Design Parameter of End Mill Based on Simulation for Three-dimensional Milling Process of Titanium Alloy[J].Design and Rasearch,2016(1):57-61.
[5] 张杨广.立铣刀几何参数对铣削系统动态特性影响规律的研究[D].济南:山东大学,2013.ZHANG Yangguang.Influences of End Mill Geometric Parameters on Milling System Dynamics[D].Jinan:Shandong University,2013.
[6] 邵子东.高速整体硬质合金立铣刀结构设计及其性能研究[D].济南:山东大学,2007.SHAO Zidong.Design of Solid Carbide End Milling Cutter for High-speed Cutting and Study of Its Property[D].Jinan:Shandong University,2007.
[7] 张晓东.整体硬质合金立铣刀CAD技术研究[D].济南:山东大学,2011.ZHANG Xiaodong.CAD Technologies for Solid Carbide End Mill[D].Jinan:Shandong University,2011.
[8] 程剑兵.钨钴类超细硬质合金刀具及其切削性能研究[D].北京:北京理工大学,2015.CHENG Jianbing.Research on Cutting Performance of WC-Co Ultrafine Cemented Carbide Cutting Tools[D].Beijing:Beijing Institute of Technology,2015.
[9] 陈颢,羊建高,王宝健,等.硬质合金刀具涂层技术现状及展望[J].硬质合金,2009,26(1):54-58.CHEN Hao,YANG Jiangao,WANG Baojian,et al.Research Status and Expectation on the Coating Techniques of Cemented Carbide Cutting Tool.[J].Cemented Carbide,2009,26(1):54-58.
[10] 彭中伟.槽铣刀螺旋槽参数优化及高速刀柄动平衡的研究[D].哈尔滨:哈尔滨理工大学,2012.PENG Zhongwei.Rasearch on Slotter Chip-hold Gloove Optimization and Handle of High-speed Dynamic Balance[D].Harbin:Harbin University of Science and Technoloy,2012.
[11] 倪高明,孙振梅,左小陈,等.具有双圆弧槽型的立铣刀:中国,CN102303158A[P].2012-01-04.NI Gaoming,SUN Zhenmei,ZUO Xiaochen et al.Groove Type End Mill with Double Arcs:China,CN102303158A[P].2012-01-04.
[12] 刘朋和.钛合金薄壁件铣削动力学特征及表面质量研究[D].沈阳:沈阳理工大学,2015.LIU Penghe.Study on the Milling Dynamic Characteristics and the Surface Quality of Titanium Alloy Thin-walled Parts[D].Shenyang:Shenyang Ligong University,2015.
[13] 王素玉,赵军,艾兴,等.高速切削表面粗糙度理论研究综述[J].机械工程师,2004(10):3-6.WANG Suyu,ZHAO Jun,AI Xing,et al.Theoretical Research of Surface Roughness for HSM[J].Mechanical Engineer,2004(10):3-6.