Study On Formation Mechanism And Active Control Technology Of Micro Slot Milling Burrs

As one of the main developing directions of advanced fabricating technology,Micro machining technology is acquiring significant applications in the domains of micro components fabrication,charactered by three dimension,flexibility,diversification and abnormal.Burr known as formed during machining process,is one of the critical issues influencing and restricting the development of precision or ultra-precision technology.With the micro-milling experiment as the foundation,the formation mechanism and active control technology are investigated systematically.The follows are the main research contents and results.(1)Burr formation mechanism and process of exit up milling side and top side are simulated and analyzed during micro slot milling on the basis of numerical simulation software,STC DEFORM-2D&3D.In the 2D simulation environment,five stages are defined for the formation process of exit up milling side burr(B1).Meanwhile,by virtue of 3D simulation function,two kinds of top side burrs are divided,videlicet,compressive burr and roll-over burr are formed under different cutting conditions.(2)Micro straight slot milling of aluminium alloy(Al601-T6)was assigned as the main experimental content,with ?0.5mm milling tool.Exit up milling side burr(B1),exit bottom burr(B2),top up milling side burr(B8)dimensions change were analyzed with the aim of acquiring the effect law exerted by cutting parameters,including blade radius,spindle speed,feed per teeth and depth of cut.Then special optimum parameter combinations for three responses characteristics were suggested respectively,within the ranges of selected process parameters.Data analysis shows that differentiation among these optimum combinations are obvious.After analyzing the stacking dimension charts between B1 and B2,phenomenon observed was that mutual dimension compensation occurred between them.(3)Four responses characteristics values were synchronously optimized by utilizing two different optimization methods,videlicet,mapping function and grey relation.The four responses included are exit up milling side burr(B1),top up milling side burr(B8),surface roughness of slot bottom(Ra)and micro milling component force(Fx).Coincident combinations of optimal factors for the above responses simultaneous optimization were suggested.While,through contrasting the value for a single response,it is revealed that somewhat distinction also exists between two optimization methods.(4)Investigation of burr active control technology was carried out.With the aim of making two top sides as up milling sides and by virtue of planned tool path,smaller dimension and uniform distribution of top up milling side burrs formed during the process,and the objective of burr active control was achieved.This special experiment may also provide valuable references for the active control of other position burrs.Research contents of this paper are vital and segmental ones belonging to the item of State Natural Science Foundation Project(NO.50175192).Significantly,parts of the research conclusions may help enrich and develop burr formation and active control theory in micro machining,and also provide certain references and application values for actual machining process.