Ball-end milling cutter design method towards the maximum material removal rate under surface roughness constraints
Ball-end milling cutter design method towards the maximum material removal rate under surface roughness constraints
复制标题
DOI：
10.1016/j.jmapro.2022.04.018
复制
发表时间：
2022-06
影响因子：
6.2
通讯作者：
Zengya Zhao;Sibao Wang;Shilong Wang;Zehua Wang;Qiang Huang;Bo Yang
中科院分区：
文献类型：
--
作者：
Zengya Zhao;Sibao Wang;Shilong Wang;Zehua Wang;Qiang Huang;Bo Yang
刀具设计和选择作为离散零件制造工艺规划中不可缺少的任务之一，从提高加工质量和加工效率的角度研究甚少。为了填补这一空白，本文研究了球头刀具的主要几何参数(螺旋角、槽数、刀具半径)对表面粗糙度和材料去除效率的影响。首先，揭示了螺旋角影响切削力系数的根本原因是斜角，而不是轴向高度或轴向位置角。提出了一种基于局部螺旋角的新型刀具切削力系数预测方法。然后，从理论和实验两个方面研究了刀具参数对表面粗糙度和MRR的影响。在此基础上，分别建立了加工质量和加工效率的刀具评价模型。采用粒子群算法(PSO)作为优化方法来搜索最优刀具。最后，提出了一种结合刀具评价模型的刀具设计方法，以获得更好的表面性能和加工效率。实验结果表明，用该方法设计的刀具在满足零件表面粗糙度要求的前提下，能最大限度地提高刀具的加工效率。这对提高零件性能、降低加工成本具有重要意义。
Cutter design and selection, as one of the indispensable tasks in discrete parts' manufacturing process planning, has seldom been investigated in terms of high machining quality and machining efficiency. In order to fill this gap, this paper studies the influences of main geometric parameters of ball-end cutter (helix angle, flute number, cutter radius) on surface roughness and material removal rate (MRR). Firstly, it is revealed that the fundamental reason why the helix angle affects the cutting force coefficients is the oblique angle, not the axial height or axial position angle. And a novel method of cutting force coefficients prediction for newly designed cutter based on local helix angle is proposed. Then, the influences of cutter parameters on surface roughness and MRR are investigated by theoretical and experimental method. Based on this analysis, cutter evaluation models for machining quality and machining efficiency are established, respectively. Particle swarm optimization (PSO) is used as optimization method to search the optimal cutter. Finally, a novel cutter design method combined with cutter evaluation models is proposed to obtain better surface performance and machining efficiency. According to the experimental results, it can be proved that the cutter designed by this method can maximize MRR under the constraint of meeting the parts' surface roughness requirements. This is of great significance for improve parts' performance and reduce machining cost.