Improving tool life in multi-axis milling of Ni-based superalloy with ball-end cutter based on the active cutting edge shift strategy
Improving tool life in multi-axis milling of Ni-based superalloy with ball-end cutter based on the active cutting edge shift strategy
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DOI：
10.1016/j.jmatprotec.2017.09.010
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发表时间：
2018-02
影响因子：
6.3
通讯作者：
M. Luo;Huan Luo;D. Zhang;K. Tang
中科院分区：
文献类型：
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作者：
M. Luo;Huan Luo;D. Zhang;K. Tang
在钛和镍基高温合金等难加工材料的铣削加工中，刀具磨损迅速增加，刀具寿命短至几分钟。此外，刀具磨损还会影响工件的几何精度和表面质量。为了提高球头刀具多轴联动加工镍基高温合金自由曲面零件的刀具寿命，提出了一种基于刀具主动刃移思想的自由曲面多轴联动铣削新策略。所提出的加工策略试图在刀具上使用不同的刃口来切割工件表面的不同部分的材料，因为每个刃口元素只能在很短的时间内用于切割。建立了刀具方位、有效刃口与刀具-工件啮合之间的关系，并将刀具磨损率近似用于预测铣削过程中各刃元的刀具寿命。根据每个刀具刃段的最大切割长度，将刀具刃口曲线和刀具接触曲线分成若干段。然后根据移动的活动切削刃规划刀具方向。进行了加工实验，结果表明，所提出的加工策略可显著提高刀具寿命。
In milling of hard-to-cut materials such as Titanium and Ni-based superalloy, tool wear increases rapidly and the tool life can be as short as a few minutes. Moreover, tool wear will influence the workpiece geometrical accuracy and surface quality. Aiming at improving the tool life in multi-axis milling of freeform workpieces made of Ni-based superalloy with a ball-end cutter, this paper introduces a new multi-axis milling strategy for freeform surfaces based on the idea of shifting the active cutting edge on the cutter. The proposed machining strategy tries to use different cutting edges on the cutter to cut the material for different portions of the workpiece surface as each edge element can only be used in the cutting for a short time. The relationships between the tool orientation, active cutting edge and cutter-workpiece engagement are established, and the tool wear rate is approximated in predicting the tool life for each edge element in the milling process. Both the cutter edge and cutter contact curve are divided into several segments according to the maximum cutting length of each cutter edge segment. Tool orientation is then planned based on the shifted active cutting edge. Cutting experiments are performed and their results show that a large improvement of tool life can be achieved by the proposed machining strategy.