难加工材料的高速铣削研究进展

目的 分析难加工材料在高速切削过程中的基本形式及其特点,归纳总结现有的高速切削理论及现象。方法 主要从难加工材料的实验现象和仿真出发,分析高速加工机理,将现有高速铣削方法及其进展进行解析。结果 高速切削在宏观领域的研究主要集中在切屑的形成与刀具磨损,而在微观加工领域,主要研究材料属性及微观结构对于加工的影响。结论 从研究趋势上看,对宏观加工模型和微观理论分析的研究均有进展,但对微观模型的研究逐渐成为了近年来的研究热点。     

不等齿距端铣刀的减振机理

本文根据切削理论及端铣过程的几何关系，提出了单齿和多齿端铣刀的铣削力模型，对不等齿距端铣刀的实质进行了分析，论述了不等齿距端铣刀的减振机理     

多齿铣刀侧铣加工多层CFRP铣削力的建模与仿真

由于碳纤维增强树脂基复合材料(CFRP)的层间结合强度较低,进行切削加工时在切削力的作用下容易出现分层和毛刺等质量缺陷。因此,通过对切削力的预测与控制可以有效提高加工质量。采用瞬时刚性力模型对多齿铣刀侧铣多层CFRP材料的加工过程进行铣削力建模与仿真,分析了多齿铣刀特有的几何结构对切削力的影响。试验中保持切削速度恒定,以不同进给速度分别对45°、0°、-45°和90°这4种典型纤维方向的单向CFRP进行侧铣加工,通过测得的切削力数据计算各自的铣削力系数。根据力学矢量叠加原理得到了多向CFRP铣削力系数的简化计算表达式,最后将计算结果代入铣削力模型得到了各时刻的铣削力仿真值。在同样的试验条件下对该多向CFRP进行侧铣加工验证试验,试验结果表明: 该模型能较好地预测铣削力,最大相对误差小于9%,平均相对误差小于5%,可为铣削参数优化和刀具结构优化提供理论基础。     

用三坐标数控铣床加工空间曲面时的圆弧插值算法

论述了在三坐标数控铣床上采用球头铣刀铣削空间复杂形面时圆弧插值的计算方法.把刀具中心等距曲线轨迹的计算归结为计算零件轮廓上点的坐标,确定了加工空间等距曲线时插值点的计算流程图.利用圆弧插值算法推导出了坐标增量计算公式,此公式可应用到数控装置修正刀具的半径,从而提高零件廓形的加工精度.此算法也可应用到端铣刀加工时圆弧插值的计算.     

基于Abaqus的微铣刀几何结构参数优化

针对微细铣削加工过程的特点,建立了微铣刀结构模型并利用Pro E软件进行了微细铣刀的结构设计,采用Abaqus软件通过有限元仿真方法比较不同结构参数的微铣刀的模态及抗断裂强度,获得了各阶模态固有频率和振型,以及微铣刀结构上的应力分布情况与特点,分析了刃口直径为50μm微铣刀的刀具悬伸量及刀具尖端几何形状对刀具性能的影响,从而获得了适合加工的几何结构参数.通过聚焦离子束(FIB)方法制备了刃口直径为50μm的微铣刀,在不同基底材料上进行了微铣削加工实验研究,并通过扫描电子显微镜(SEM)高分辨率地观测并分析了铣削效果以及微铣刀的磨损情况,探讨了几何形状以及实际偏心量对刀具的影响并评价了不同几何形状微铣刀的性能.     

浅谈铣床的应用

铣床是用铣刀对工件进行铣削加工的机床。铣床除能铣削平面、沟槽、轮齿、螺纹和花键轴外,还能加工比较复杂的型面,在机械制造和修理部门得到广泛应用。铣刀的种类很多,按铣刀结构和安装方法可分为带柄铣刀和带孔铣刀。铣床夹具主要用于加工零件上的平面、凹槽、键槽、花键、缺口及各种成形面。铣床也存在缺点,但是它的优点是主要的,铣床有良好的发展趋势。     

微铣刀刀刃轨迹预测模型及影响因素分析

微铣削是一种柔性很强的微加工方法,可对多种材料进行微器件的加工.但由于微铣刀具有独特的几何特征,微铣削时的刀刃轨迹与传统意义上的铣削刀刃轨迹有明显区别.针对2刃微铣刀,开发了一个考虑刀具回转误差和转子振动效应的刀刃轨迹预测模型,并分析了其对加工过程的影响.同时提出了一种基于刀柄测量结果,计算刀尖回转误差和刀具装夹不平衡量的方法.将这两个结果输入刀刃轨迹模型后,可以准确地预测刀尖中心和两个刀刃的轨迹,并以此来计算即时切屑厚度、切削力、铣槽宽度(加工误差)和表面质量.实验结果很好地验证了模型的预测.分析结果表明,在微铣削过程中,单刃切削经常发生;刀刃角和进给角这两个模型参数对加工误差和刀具磨损非常重要,刀刃角的最优值为±90°,进给角可根据加工要求进行选择.     

螺纹数控铣削方法与编程、加工

叙述数控铣床螺纹的加工方法、螺纹铣削的铣刀类型,螺纹铣削方式,刀具半径补偿在螺纹数控铣削中的应用及螺纹编程与技巧。     

数控铣削螺纹加工

数控铣削螺纹的加工有多种形式，根据螺纹的特点与类型，选择加工方法：对于小孔采用螺纹钻削循环，对于大孔采用单刃螺纹铣刀加工内螺纹：这里主要介绍螺纹的单个螺距铣削编程指令和利用参数化即宏程序的编程。     

基于隐式Adams方法的螺旋曲面铣削系统稳定性预测研究EI北大核心CSCD

针对螺杆转子铣削过程中的铣削系统稳定性进行研究。首先通过模态试验获取刀具的模态参数。其次,根据盘铣刀铣削螺杆转子曲面原理建立三自由度铣削力模型和以线性时滞微分方程表示再生型颤振影响的铣削加工动力学模型,并对刀齿铣削周期进行离散。然后,提出基于隐式Adams对螺旋曲面铣削系统稳定性进行预测的方法,在利用隐式Adams方法对动力学方程进行数值求解的基础上,依据Floquet理论判断系统的稳定性,获得螺旋曲面铣削系统的稳定性叶瓣图。最终,根据稳定性叶瓣图选取加工参数进行试验,验证隐式Adams方法在螺旋曲面铣削系统的适用性。试验结果表明:数值求解结果与试验结果吻合程度较高,即采用的隐式Adams方法适用于螺旋曲面铣削系统的稳定性预测。     

The influence of cutting force on surface machining quality

Appropriately controlled cutting forces can contribute not only to the safety and efficiency of machining but also to the quality of machined surfaces. It is even more important when hardened material is cut. The correlation between the cutting force and the surface quality in ball-end milling operations has been investigated by machining P20 steel (HRC 30) work-pieces using solid carbide ball-end cutters. Plane surfaces with different depth of cut were machined using two different cutting strategies. The first strategy cut the test-piece using a cutting force model, whereas the other machined with a feed rate optimization product, which uses the removal rate as an analogue of cutting force to control the feed rate. The test results show that constant surface quality is possible when the cutting forces are controlled through feed rate adjustment. Conversely, a desired surface quality can also be maintained by controlling the cutting force in a predetermined manner.     

Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

The in-situ TiB₂ particle reinforced aluminum matrix composites are materials that are difficult to machine, owing to hard ceramic particles in the matrix. In the milling process, the polycrystalline diamond (PCD) tools are used for machining these materials instead of carbide cutting tools, which significantly increase the machining cost. In this study, ultrasonic vibration method was applied for milling in-situ TiB₂/7050Al metal matrix composites using a TiAlN coated carbide end milling tool. To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling (UAM), the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail. Additionally, a comparative experimental study with and without ultrasonic vibration was carried out to investigate the influences of ultrasonic vibration and cutting parameters on the cutting force, tool life and tool wear mechanism. The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period, in ultrasonic vibration assisted cutting. Large instantaneous acceleration can be obtained in axial ultrasonic vibration milling. The cutting force in axial direction is significantly reduced by 42%-57%, 40%-57% and 44%-54%, at different cutting speeds, feed rates and cutting depths, respectively, compared with that in conventional milling. Additionally, the tool life is prolonged approximately 2-5 times when the ultrasonic vibration method is applied. The tool wear pattern microcracks are only found in UAM. These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB₂/7050Al metal matrix composites.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00294-2     

Flank milling model for tool path programming of turbine blisks and compressors

In this paper, a methodology for complex surface machining based on cutting forces prediction is presented. The work is focused on blade finishing operations. The cutting forces model developed can be applied to three axis and five axis milling cases. For three-axis cases, the chip thickness is calculated according to traditional analytical methods. On the contrary, for five-axis cases the chip thickness is obtained from a geometric method developed in the paper. The cutting forces values can be calculated for the complete toolpath, but the presented model can also provide the programmer information about the cutting forces in a single point of the toolpath. The cutting force model is integrated in the CAM software in order to provide an extra tool that helps the programmer to decide which the optimal milling strategy is, based on the minimum cutting forces. In the last section, results of a case study based on impeller and blisk blades flank milling are discussed. Model predicted forces and real measured forces of flank milling operations are compared for model validation. Applying this methodology, cutting forces can be taken into account as a decisive criterion for optimal tool path selection.     

Prediction of cutting force based on machining parameters on AL7075-T6 aluminum alloy by response surface methodology in end milling

Cutting forces modeling is the basic to understand the cutting process, which should be kept in minimum to reduce tool deflection, vibration, tool wear and optimize the process parameters in order to obtain a high quality product within minimum machining time. In this paper a statistical model has been developed to predict cutting force in terms of geometrical parameters such as rake angle, nose radius of cutting tool and machining parameters such as cutting speed, cutting feed and axial depth of cut. Response surface methodology experimental design was employed for conducting experiments. The work piece material is Aluminum (Al 7075-T6) and the tool used is high speed steel end mill cutter with different tool geometry. The cutting forces are measured using three axis milling tool dynamometer. The second order mathematical model in terms of machining parameters is developed for predicting cutting forces. The adequacy of the model is checked by employing ANOVA. The direct effect of the process parameter with cutting forces are analyzed, which helps to select process parameter in order to keep cutting forces minimum, which ensures the stability of end milling process. The study observed that feed rate has the highest statistical and physical influence on cutting force.     

A study on milling of glass fiber reinforced plastics manufactured by hand-lay up using statistical analysis (ANOVA)

Milling is the most practical machining (corrective) operation for removing excess material to produce a well defined and high quality surface. However, milling composite materials presents a number of problems such as surface delamination associated with the characteristics of the material and the cutting parameters used. In order to minimize these problem is presented a study with the objective of evaluating the cutting parameters (cutting velocity and feed rate) related to machining force in the workpiece, delamination factor, surface roughness and international dimensional precision in two GFRP composite materials (Viapal VUP 9731 and ATLAC 382-05). A plan of experiments, based on an orthogonal array, was established considering milling with prefixed cutting parameters. Finally an analysis of variance (ANOVA) was preformed to investigate the cutting characteristics of GFRP composite materials using a cemented carbide (K10) end mill.     

Multi-attribute optimization of end milling epoxy granite composites using TOPSIS

Epoxy granite composites are identified and recognized as better materials for machine tool applications due to inherent damping properties. However, end milling of these composites has not been explored much. Milling of epoxy granite composites presents a number of problems, namely, cutting forces and surface roughness appear during machining. This research work focuses on end milling of epoxy granite composite specimens using high-speed steel end mill cutter by varying the cutting conditions such as spindle speed and feed with a uniform depth of cut and selection of optimal machining parameters. The experimental runs of 27 different trials were carried out and three different attributes such as thrust force, tangential force, and surface roughness were analyzed. This research work presents a sequential procedure for machining parameters selection. Selection of optimal machining parameters is done on the basis of Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method.     

Study of milling force variation in ultrasonic vibration-assisted end milling

Ultrasonic vibration cutting has been proved to be an effective cutting technology for its excellent cutting performance and has been widely applied in turning and drilling process. However, this kind of technology is rarely tried in milling process. In cutting process, cutting force is an important process parameter, which affects surface finish and tool wear. This paper investigates the milling force variation in ultrasonic vibration-assisted end milling process through a series of slot-milling experiments. The main research contents include two parts, one is the effect of the externally excited vibration on milling force in milling process, and the other is the influence of milling and vibrating parameters matching on milling force value. Experimental results show that ultrasonic vibration can change traditional milling conditions, realize separate-type milling, obtain similar pulse-like profiles of cutting forces, reduce average cutting force value; and the peak value of the feed direction cutting force can also be greatly decreased by adopting reasonable vibration amplitude, an optimal combination of machining parameters is of great benefit to achieving small cutting force. According to the experimental findings, ultrasonic vibration-assisted milling is a prospective technology to achieve precision milling of small part.     

A cortical bone milling force model based on orthogonal cutting distribution method

In orthopedic surgery, the bone milling force has attracted attention owing to its significant influence on bone cracks and the breaking of tools. It is necessary to build a milling force model to improve the process of bone milling. This paper proposes a cortical bone milling force model based on the orthogonal cutting distribution method (OCDM), explaining the effect of anisotropic bone materials on milling force. According to the model, the bone milling force could be represented by the equivalent effect of a transient cutting force in a rotating period, and the transient milling force could be calculated by the transient milling force coefficients, cutting thickness, and cutting width. Based on the OCDM, the change in transient cutting force coefficients during slotting can be described by using a quadratic polynomial. Subsequently, the force model is updated for robotic bone milling, considering the low stiffness of the robot arm. Next, an experimental platform for robotic bone milling is built to simulate the milling process in clinical operation, and the machining signal is employed to calculate the milling force. Finally, according to the experimental result, the rationality of the force model is verified by the contrast between the measured and predicted forces. The milling force model can satisfy the accuracy requirement for predicting the milling force in the different processing directions, and it could promote the development of force control in orthopedic surgery.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00300-7     

Investigations on hard machining of Impax Hi Hard tool steel

In this paper, experimental investigations are carried out by end milling process on hardened tool steel, Impax Hi Hard (Hardness 55 HRC) a newly developed tool steel material used by tool and die making industries. Experiments are performed with an aim to study performance investigations of machining parameters such as cutting speed, feed, depth of cut and width of cut with consideration of multiple responses viz. volume of material removed, tool wear, tool life and surface finish to evaluate the performance of PVD coated carbide inserts and ball end mill cutters. It has been observed through scanning electron microscope, X-ray diffraction technique (EDX) that chipping and adhesion are active tool wear mechanisms and saw-toothed chips are formed while machining of Impax Hi Hard steel. It is also noticed out that tool life is not enhanced while machining with minimum quantity lubricant than dry machining. From the investigations, it is observed that hard machining can be considered as an alternative to grinding and EDM, traditional methods of machining difficult-to-machine materials i.e. hardened steel with hardness greater than 50 HRC with a scope of improved productivity, increased flexibility, decreased capital expenses and reduced environmental waste.