Study On Cutting Stability And Structural Design Method Of High Speed Face Milling Cutter

High speed face milling cutter is a representative high speed cutter, and its machining technology on high speed cutting aluminum alloy has become preferential process for high speed milling large aluminum alloy integral components of aerospace product, it is widely adopted in high speed milling and has excellent efficiency and high precision.The cutting stability and collaborative design of cutter has become one of the key issues in development and application of high speed face milling cutter with indexable inserts. At present, there are few researches on cutting stability of high speed face milling cutter, its design theory and methods, which limits the development of high speed milling technique seriously.In order to realize safety, stability and high efficiency cutting, and acquire collaborative optimization design method of cutter, based on high speed cutting theory and the achievement of interrelated investigation, the paper adopts grey system theory, cutting vibration and cutting dynamics theory, axiom design theory and optimization design method, and researches cutting stability and structural design method of high speed face milling cutter.In allusion to indeterminacy of influencing factor and evaluating goal on safety and stability of high speed milling induced by small sample and lacking information, this work established safety criterion of high speed face milling cutter which taked into account of failure influence of resonance, propounded safety and stability cutting conditions of cutter, and realized the prediction of security and stability of cutter using FEM and Penghuanwu discriminance. Analysed absolute degree of incidence on the safety and stability of cutter using grey system theory, the influence laws of structre parameters of cutter and their interaction on cutting safety and stability were acquired. Idling of cutter and high speed milling experiments were carried out, and analysed relative degree of incidence on cutting force of per unit area in experiment, results validated the dependability and validity of safety and stability cutting criterion.According to dynamic cutting model and dynamics differential equations of high speed face milling cutter, the vibration models of centrifugal force and dynamic cutting force were established, and obtained the laws of cutting vibration. Aim at the problems of process system for high speed milling, such as modeling, detecting and evaluating on dynamic characteristic, the frequency spectrum functions of dynamic cutting forces were constructed, and propounded evaluating method of dynamic face milling performance. By means of experiment, the influence of distribution of cutter teeth on dynamic milling performance was investigated, and proposed the universal method for depressing vibration of high speed face milling cutter.In basis of the most cutting temperature and the most ratio of the heat diffusing into workpiece, the model of cutting speed was constructed. The condition to determine surface roughness according to feed was put forward, and established the model of maximal residue height on machining surface based on the effects of cutting vibration and axial error of cutter. According to experiment data of surface roughness in high speed face milling aluminum alloy, the model of cutting behavior characteristics was established using grey system theory, results of synthetic degree of incidence validated the model of maximal residue height, and attained the influence rules of cutter on cutting stability and efficiency.Using grey system theory in axiomatic design of high speed face milling cutter, the structural design method of cutter was investigated. The problem of parameters interaction and functions coupling in axiomatic design of high speed face milling cutter was solved using the analysis method of grey cluster, and realized the reconstruction of design matrix and collaborative design planning. The method was extended to optimize design of the bottom function and modeling in high speed face milling cutter, established the optimal design model of cutter teeth, proposed optimization method of indexable inserts based on feature matching and cutting speed, constructed the model of optimization design for dynamic balance accuracy of high speed face milling cutter based on grey incidence analysis. Results showed that there was not design loop which existed in the development of high speed milling cutter, the effects of simplifying design process and shortening design cycle improving collaborative design were validated in development of high speed face milling cutter. Results of fuzzy object element analysis based on experiment indicated that cutting vibration of high speed face milling cutter using structural design method was depressed, the cutters with higher safety and cutting stability, and their cutting performance have met the requirement of high speed milling.