Analysis Of High-speed Milling Experiment And Prediction Of Machining Stability On Aluminum Silicon Alloy ADC12

High-speed cutting (HSC) technology is characterized by a high material removal rate, small cutting force, small distortion and high processing precision, etc. and the application in the engine cylinder block, cylinder head processing increasing. However, there is no stable and reliable technical guidance in actual production due to the lack of High-speed cutting mechanism and basic research in our country. The practical situation in the factory is that the spindle rotational speed is lower than design, cutting parameters is needed to optimize, utilization rate of machine tools is in lower level and failed to take the advantages of high speed machining center.This paper carried out experimental research of High-speed milling(HSM) technology in the application on material of the cylinder block, cylinder head-aluminum silicon alloy ADC12processing based on High-speed cutting technology research status and requirement of actual production, and the specific content is as follows:Firstly, the influence of spindle speed, feed per tooth and axial cutting depth on surface roughness were explored based on the single factor experiment of surface roughness; The prominence order of the these factors was calculated through variance analysis of the result of orthogonal experiment.Secondly, taking the data of orthogonal experiment as the training sample, combining the advantage of fuzzy logic and neural network,the predictive model of surface roughness which was based on T-S fuzzy neural network was established. The average prediction error of this model was3.3%and the accuracy of this model is96.7%.So it can be used to predict the surface roughness of aluminum silicon alloy in the high speed machining process accurately.Thirdly, the mechanical cutting force model of end milling process was established based on oblique cutting theory, the instantaneous cutting force distribution state in space in the spiral milling condition was analyzed; the influence of spindle speed, feed per tooth, axial cutting depth (with large radial cutting depth and small the cutting depth) and radial cutting depth (with large axial cutting depth and small axial cutting depth) on the cutting force was explored based on the single factor experiment of cutting force; Orthogonal experiment of cutting force was carried out and the prominence order of the these factors was calculated through variance analysis. It can be concluded that the influence of axial cutting depth, spindle speed on cutting force was greater.Finally, the critical axial cutting depth formula for achieving stable machining was deduced based on the dynamic cutting regenerative thickness model and unit dynamic milling force theory. With the modal parameters of the system and cutting parameters of milling force which was obtained by the experiment, the stability Lobes diagram of high speed milling of aluminum silicon alloy ADC12was built. By the stability Lobes diagram, optimize axial cutting depth and the spindle speed which have avoid cutting chatter area can be made conveniently. It has a certain practical significance in the actual production.