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On the Development of Curved-Shape End Mill for Suppressing Machining Vibration in the Mold Machining Process with Cutting Simulation

切削模拟抑制模具加工过程中加工振动的曲线形立铣刀的研制

基本信息

批准号：
13650135
负责人：
MATSUMURA Takashi
金额：
$ 2.11万
依托单位：
Tokyo Denki University
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (C)
财政年份：
2001
资助国家：
日本
起止时间：
2001 至 2002
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-13650135/
关键词：
end mill cutting force chatter vibration ball end mill roughing end mill cutting simulation mold machining CAE 金型

项目摘要

This study develops an analysis to predict cutting force and tool displacement and shows a design of tool geometry to suppress tool vibration in the machining with curved-shape end mill. The analysis based shear plane model can calculates cutting force with orthogonal cutting date, which can be obtained in a few cutting tests. The developed analysis can be verified in the examples of milling process with insert-type ball end mill and roughing end mill. Then an analysis can be developed to predict tool displacement with cutting force. Dynamic characteristics in cutting process during rotating cutting edge are measured to solve vibration equation in analysis. It is shown that dynamic characteristics change with cutter rotation. The analysis based on the characteristics shows the machined surface in down-cut process is better than that of up-cut process.The effect of tool geometry on cutting force is investigated with the developed analysis. It is proved that ball end mill having chip reduced contact length can reduce cutting force in the analysis and experimental results. Tool displacement analysis is examined in the milling process with tool having chip reduced contact length. It is proved that chip reduce contact length has a large effect to suppress tool vibration with reducing cutting force.This study can contribute to reducing the term for developing new tool geometries in the cutting tool industry ; and to operation planning with predicting process troubles in mold machining industry.

本文分析了曲面立铣刀加工过程中切削力和刀具位移的预测，并提出了抑制刀具振动的刀具几何设计。基于分析的剪切面模型可以用正交化的切削量计算切削力，可以通过几次切割试验获得切削力。通过插入式球头立铣刀和粗立铣刀的铣削加工实例，验证了分析的正确性。然后，可以用切削力进行分析来预测刀具位移。在分析中，测量了旋转刃口过程中的动态特性，求解了振动方程。结果表明，动态特性随刀具转速变化而变化。基于特征的分析表明，下切削加工表面优于上切削加工表面。在此基础上分析了刀具几何形状对切削力的影响。分析和实验结果证明，采用减少切屑接触长度的球头立铣刀可以减小切削力。在刀具切屑减少接触长度的情况下，研究了刀具在铣削过程中的位移分析。实践证明，切屑减少接触长度对减小切削力抑制刀具振动有很大的作用，该研究有助于降低刀具行业开发新刀具几何形状的条件，并为模具加工行业的作业计划和工艺故障预测提供依据。