Prediction Of Milling Process And Analysis Of Surface Quality For TC4

TC4 Titanium alloy has high strength, high corrosion resistance and ability to withstand extreme temperatures, which makes it widely used in aviation, aerospace, marine and medical industry. However, the properties of low thermal conductivity, low elastic modulus and active chemical performance make it difficult to machine, such as the cutting forces are large, vibration is serious, the processing surfaces are rough and the processing efficiency is low. In order to study the processing of Titanium alloy, some relevant researches have been done in this paper, which contain the prediction of static cutting force, the simulation of dynamic cutting force, the prediction of cutting stability, the prediction of surface roughness and the optimization of cutting parameters.An exponential model for predicting static milling force has been established based on data collected from orthogonal milling experiments. Then the affection of the cutting parameters, tool structure and coating on cutting forces is analyzed, which provides guidance for choosing proper parameter and tool type in the milling process of TC4 alloy. In the section of the simulation of dynamic cutting force, a model based on mechanical theory has been proposed. Based on linear approximation in small range, this method can calculate the cutting coefficients varying with the cutting parameters without ignoring the edge forces, which makes the simulated result accurate. The prediction of cutting stability has been further studied on the basis of the simulation of dynamic cutting force. In the section, a prediction method for stable cutting region has been proposed to obtain the ultimate stable map under different cutting parameters based on the first-order linear ordinary differential equations. This method helps to choose parameters to guarantee the stability of the cutting system.A model is constructed to describe the relationship between surface roughness and cutting parameters based on quadratic response surface method and the affection of cutting parameters on surface roughness is analyzed. Meanwhile, the cutting parameters are optimized by genetic algorithms with the goal of material removal efficiency, which provide guidance to choose parameters in the cutting process of TC4 alloy.The relevant researches on the processing of titanium alloy in this paper have enriched the theory to some extent. The researches have provided powerful guidance for developing processing program, obtaining reasonable milling parameters and for improving the processing efficiency of titanium.