Tool Structures Design For Milling Titanium Thin-walled Parts

Titanium is an important structural metal which possesses the advantage of heat resistance, corrosion resistance and strength advantages. Titanium has been widely used in various fields. Serious chilled phenomenon of titanium, the cutting temperature, the greater cutting force per unit area and easy tool wear make titanium a typical difficult machining materials. Thin-walled parts are composed of a number of sidewalls and webs. Titanium thin-walled parts are widely used in the aviation industry for its material savings, compact and light weight. Thin wall structural components are complex, low stiffness, low positioning accuracy, vibration and poor process. Vibration, heat and stress cause rapid tool wear in the process of machining titanium thin-walled parts. Take the Ti-6A1-4V and Ti-6A1-4V thin-walled parts as the research object by means of theoretical analysis, finite element simulation and test, the structures of end mills are chosen to mill Ti-6Al-4V providing some support for the structural optimization of end mills.The tool tip structure selected. Based on the milling parameters and corner radiuses the milling types are classified. According to the milling types, the most common milling type is chosen. Then the face milling force model is established for the most common milling type. The milling experiment is conducted. The effectiveness of the model is validated. The law on the impact of variation in the corner radius for milling force is analyzed. At last the proper corner radius is chosen to mill Ti-6A1-4V.Based on the material properties of Ti-6Al-4V, the single-factor test method is conducted to analyze the law which is the impact of different rake angles, different flank angles and helix angles on cutting forces, temperature, mises stress and chip thickness.On the basis of the aforementioned study, rake angle, flank angle and helix angle are taken as factors. The orthogonal experiments are adopted based on the factors. End mills of different geometric parameters are designed by use of3D graphics software. The end mills are imported to the finite element software, then the influence of tool structures on the deformation of thin-walled components are studied. The tool structures to mill thin-wall parts of titanium are optimized.