Modeling Simulation And Testing On Ball-End Milling Of Jointed Hardened Steels

Milling of hardened steels of automobile Panel die has now become a key technology of the major development and research of automobile manufacturing industry, which directly reflects the level of vehicle dies manufacturing. Due to the combination of multiple quenching hard steel material of this die type, cutter often mill two kinds or more materials during a milling period. However in the transition region of two materials, milling cut force value will occur to be complex, this changes may lead to other problems, such as sharp wear of cutter, decrease of surface quality. At present, studies of milling cut force value in the transition region of different hardness hardened steel are very lack. So, this study has a very important theoretical value and practical significance. This paper mainly contains three points below:1. Build a flexible milling force model of single hardness hardened steel on the foundation of theories of metal cutting, cutter deformation and system identification. This model is based on experience coefficient model, which considers the factor of surface incline, deformation and decentration of cutters, and corresponds to the basic conditions of the transition region of the model to be established, which offer a reference of the new model.2. Build a milling force experience coefficient model on incline of transition region of hardened steels, based on milling force model of single hardness hardened steel. The transition area is divided into parts, the instantaneous micro-milling forces are according to the conditions in the different regions, and the resultant milling force is calculated by the integration of micro-milling forces.3. As the uneven levels of test factors features, this paper adopt a hybrid design, with spindle speed n and feed rate f using uniform design, the remaining parameters orthogonal design. The measurement data is analyzed, and the correctness of the model is verified, by milling the combination of Cr12MoV of different hardness. While, the milling forces under various kinds conditions and in all directions are analyzed, through the statistical test results, especially the effect of the angle of inclination to the changes of milling force in the transition region.