摘要
本文在球头铣刀理论铣削力模型基础上,考虑高速加工切屑惯性力,建立了单元铣削力模型,并针对深型腔的加工铣刀变形,建立了球头铣刀变形铣削力模型,给出了曲面曲率变化的切入提前角和切出滞后角的切削区间模型。
在许多模具和复杂零件中的曲面型腔加工需要采用细长杆球头铣刀,因此在铣刀变形铣削力模型基础上,针对动态铣削中细长杆球头铣刀振动和工件表面波纹对切削厚度的再生反馈建立了动态铣削力模型,并在ANSYS中进行模态分析,得出铣削刀具的模态固有振动频率,为球头铣刀截面系数的求解提供必要的数据。
铣刀在铣削时的振动位移是影响工件加工质量的重要因素之一。本文利用MATLAB/GUI工具对动态铣削力模型和振动位移模型进行了仿真分析,研究了铣削参数对铣刀在曲面高速铣削时动态铣削力和振动位移的影响。论文通过曲面高速铣削实验实测铣削力,并与仿真结果对比,仿真与实测结果之间的相对误差较小,证明了模型的正确性。
论文利用动态铣削力模型和振动位移模型对高速铣削加工中振动进行了预测研究,进而可以优化切削参数,并可为曲面高速加工中刀具运动轨迹优化提供参考,以延长刀具寿命,并提高加工工件的表面质量。
Considering the inertial force of high speed milling, the elemental force componentsare established based on the cutting force model of ball end milling, and the cutting forcemodel of ball end milling which is used to mill the deep contour with considering springdeflection is established. In view of the feature of ball end milling process, the model ofaccurate cutting area is presented which considers the advance angle of cutting in and thelag angle of cutting off with considering the curvature of machined surface.
Considering the feedback of dynamic deflection of the cutter and vibration mark onthe milled surface on the transient chip thickness, the dynamic model of the regenerativemilling force is constructed based on the cutting force model of ball end milling which isused to mill the deep contour with considering spring deflection. Carrying on modelanalyze through ANSYS software to milling cutter, study the natural frequency of ball endmilling,and provide some data for the cutter effective cross section coefficient.
The milling cutter's vibration displacement in the milling process is one of the mainelements which influence the accuracy of the work piece. The MATLAB/GUI is used tothe dynamic model of the regenerative milling force and the model of vibrationdisplacement; we can research the influence of the high speed surface machining processparameters for the vibration displacement and the regenerative dynamic milling force ofhigh speed surface machining. In the high speed milling experiment research, a series ofexperiment shave have been carried out to get milling force data. By comparison with thepredicted milling force, it is shown that the simulation errors is small, which proves thecorrectness of the model.
The vibration displacement of the high speed milling based on the dynamic model ofthe regenerative milling force and the model of vibration displacement has been researched,then the optimized parameter choices has been offered, and these establish the basis forchoosing the tool path of high-speed cutting, these are advantageous in strengthening thecutting tool life, and enhance the high speed surface machining process quality.
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