球头铣刀铣削斜面的三维有限元仿真研究

在能源动力、汽车、航空航天、模具制造等关键零部件的加工过程中,球头铣刀因其特有的刀具几何结构,常作为零件加工的最终成型刀具。考虑到在球头铣刀立铣加工中不同的刀具与工件相对姿态会对切削过程产生不同的影响,本文研究切屑形成和不同走刀方式下切削过程中各物理量(切削力、切削温度等)的变化情况,结合有限元仿真技术在切削加工中的应用,建立硬质合金球头铣刀铣削斜面的有限元模型,模拟相同切削参数下,八种不同走刀方式的球头铣削过程,分析刀具切入切出工件时切屑的形成过程,探究切削力和切削温度的变化规律。仿真结果表明:不同的走刀方式,平均切削合力各不相同,同时切屑和工件的最大切削温度也出现较大差异,而斜坡上坡逆铣的走刀方式所对应的平均切削合力和最大切削温度均最优。

Investigation on 3D Finite Element Analysis of Ball-end Milling with Tool-workpiece Inclination

In the manufacturing process of key components involving the fields of energy power, automotive, aerospace, and mould making, ball end mill often acts as the final cutting tool for processing the parts because of its special milling cutter geometrical structure. Considering that different tool-workpiece postures would produce different effects on the machining process in hall end milling process, this paper mainly focused on the chips formation process and the variation conditions of physical quantities （cutting forces and cutting temperature） in cutting process under different machining strategies. Combining the application of the finite element simulation technology in cutting process, the finite element model with regard to the cemented carbide ball end mill machining the surface with the feature of inclination angle was developed. The ball end milling processes with eight different tool path modes corresponding to the same cutting parameters were simulated, and the chip formation process when the cutter cutting into and cutting out the workpiece was analyzed. Moreover, the variation trends of the cutting forces and cutting temperatures were demonstrated. The results show that the resultant values of the mean cutting forces are different from each other under various tool path modes, and the maximum cutting temperatures in the chip and workpiece present significant changes. As a result, the tool path mode of upward-up-milling is the best choice corresponding to the optimal resultant value of the mean cutting forces and the cut-ting temperature.