可变径向切深下螺旋齿球头铣刀微细铣削

微细铣削加工是使用微型立铣刀在高主轴转速下制造微型元件的加工方式,分析切削力和加工稳定性对表征微细铣削加工过程起着重要的作用。提出一种数值分析的方法来研究螺旋齿球头立铣刀在可变径向切削深度下的微细铣削加工过程。首先建立了球头铣刀微细铣削的模型,并推导了切削力的计算公式;采用时域仿真的方法详细计算了螺旋齿球头立铣刀和平头立铣刀铣削加工的切削力,并对比了二者切削力仿真的结果;通过时域和频域研究相结合的方式详细分析了小径向切深下球头铣刀微细铣削的稳定性。最后,分析得到了Hopf-flip分岔,并深入对比和分析了不同加工条件下铣削加工的稳定性状况。

Investigation of helical ball micro milling with variable radial immersion

Micro milling can fabricate miniaturized components using micro end mill at high rotational speeds. The analysis of cutting force and stability in micro milling plays an important role in characterizing the cutting process. A numerical analysis method is presented to investigate the helical ball micro milling process with variable radial immersion. The schematic model of ball micro milling is constructed and the cutting force calculation formula is derived. And then, a detailed time domain simulation for micro milling forces between helical ball and square end mills is carried out, and the results are compared. In addition, the stability lobe of ball micro milling with low radial immersion is researched in detail through time domain and frequency domain methods. Finally, the Hopf and flip bifurcations are explored and the simulation results between variable stability cases are deeply compared and analyzed.