Inverse cutting technology - a new strategy in face milling

逆向切削技术——面铣新策略

• 批准号: 316141494
• 负责人: Professor Dr.-Ing. Bernhard Karpuschewski, since 12/2020
• 金额: --
• 依托单位: Gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V.
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/316141494?language=en
• 关键词: Inverse; cutting; technology; new; strategy

The proposal based on the running project GZ: (sign removed) aims to improve process stability at increasing productivity in face milling. This is realised by reducing the cutting ratio b/h (undeformed chip width b to undeformed chip thickness h). If the strategy of low cutting ratio is realised up to b/h < 1, many cutting parameters and mechanisms are inverted. It can be referred to as “inverse” cutting technology. Adapting cutting parameter (decreasing the depth of cut ap and increasing the feed per tooth fz) to the lowest cutting ratio, the cutting process is stabilized. With decreasing cutting ratio the direction of the declination force vector turns towards the spindle axis. Accordingly, a low cutting ratio has a positive effect on process dynamics.The project objective contains topics from basic investigations on the effect of the inverse cutting ratios on cutting force, process dynamics and process temperature in milling, which are leading to practical process and tool design. The main milestones are the development of models for calculation of process forces, tool deflection und residual stresses, investigations on stepped cutting and helical positioning of the cutting edges, extension of the Kienzle force model, design of micro and macro tool geometry, investigation on cutting speed influence on surface integrity at inverse cutting. Finally, the combination of inverse chip formation and high-speed cutting is intended to significantly optimize the face milling process in terms of surface integrity and productivity.

该提案基于正在运行的项目GZ:（删除符号），旨在提高工艺稳定性，提高面铣削生产率。这是通过降低切削比b/h（未变形切屑宽度b到未变形切屑厚度h）来实现的。如果在b/h < 1以下实现低切削比策略，则许多切削参数和机理将被逆转。它可以被称为“逆”切割技术。将切削参数（减小切削深度和增加每齿进给量fz）调整到最低切削比，使切削过程稳定。随着切削比的减小，偏角力矢量的方向向主轴方向偏移。因此，低切削比对过程动力学有积极的影响。项目目标包括对铣削过程中反切削比对切削力、过程动力学和过程温度的影响的基础研究，这些研究将导致实际的工艺和刀具设计。主要里程碑是建立了加工力、刀具挠度和残余应力的计算模型，研究了阶梯切削和切削刃的螺旋定位，扩展了Kienzle力模型，设计了刀具的微观和宏观几何形状，研究了切削速度对反切削时表面完整性的影响。最后，将反切屑形成与高速切削相结合，旨在从表面完整性和生产率方面显著优化面铣削工艺。