High Speed/Ultra-High Speed Milling Stability Based On Equivalent Profile Of Cutter

As an important basic technology, High/ultra-high speed milling possessed outstanding advantages of high efficiency and high precision has become an important part of the advanced manufacturing technology in the21st century, which has been widely used in aerospace, automotive, mold, energy, and many other fields. In high speed milling conditions, the influence of instable machining caused by vibration in machining process on efficiency, surface quality, production cost as well as use time of machines and tools is larger than conventional cutting speed. The study of the high/ultra-high speed milling stability is very important to improve the cutting efficiency, security processing precision. Taking the stability prediction of high-speed milling and Safety evaluation as object, the method of Equivalent profile of milling cutter is carried out through underlying and systematical investigation of the stability of high/ultra-high speed milling.Studying the dynamic model and modeling method suit to the characteristics of high/ultra-high speed milling system, the dynamics model of high/ultra-high speed milling system are set up with respect to the influence of gyroscopic moment due to high rotating speed, spindle/holder connection form, end milling cutter with different length of overhang on dynamic characteristics of system. The influences of spindle speed, gyroscopic effect on Tool trajectory are investigated respectively. Get the trajectory of central point in face milling by the method of theoretical analysis and finite element simulation at different speeds, then obtain the Equivalent profile of milling cutter without speed.Obtain the instantaneous uncut thickness based on the equivalent profile of milling cutter,buliding the model of instantanous cutting force,and studying the influences of speed to cutting force; fixed the dynameic model of system based this cutting force model,getting the dynamic model of high/ultra-high speed milling system considering the speed.Based on the dynamic model of high/ultra-high speed milling system and the force model of the instantaneous cutting force, The stability limit diagram used as a representation of milling stability is proposed, which is the theoretical basis of prediction, evaluation and optimization. Analyze the stability of high speed/ultra-high speed milling system with Equivalent profile of milling cutter, spindle/holder connection form, end milling cutter with different length of overhang. On the base of achieved method in the stability limit diagram prediction, the stability prediction and evaluation system of high/ultra-high speed milling is builded. Provide the theory basis for high/ultra-high speed milling stability and optimization.