Integrated Simulation Optimization Method For Geometric Parameters Of Ball- End Milling Cutter

With the advent of new materials and new processes,the universal tool with fixed traditional parameters is difficult to meet the flexible requirements of modern manufacturing.Tool geometry parameters affect the cutting force and cutting temperature during the cutting process,while force and temperature are the main causes of tool wear and failure,and also affect the shape and quality of the machined surface.At present,most scholars at home and abroad study the tool parameters as known quantities,instead of designing high-performance tools with special properties for specific machining objects,and the tool geometric parameters are related to each other.It is not possible to select a certain parameter in isolation.Optimizing tool geometry is an effective means to improve cutting performance under certain cutting conditions.The use of test methods to analyze metal cutting processes requires high-precision equipment and testing instruments as support,and the cost is high.With the rapid development of modern computer technology,quantitative simulation technology based on finite element theory has become a powerful tool for studying cutting and tool optimization,but its automation is low,and the modeling period of the tool and pre-simulation processing is long.In order to make the geometrical parameters optimization design of milling cutter more efficient,this paper proposes a method of integrating simulation to optimize the geometric parameters of the tool,and studies the key technologies of Isight integrated UG and ABAQUS software,and expounds the necessary documents and acquisition methods in the integration process.Firstly,the structural characteristics of the ball-end milling cutter are analyzed,and the tool feature variable expression text,the ball end mill parameterized model file and the UG model update code program required for Isight integration UG are established.Then base on the key technology of finite element cutting simulation,the finite element simulation model of 3D milling required for integration is established,and the simulation results are verified by experiments.At the same time,base on the modeling steps,the simulation modeling code program integrating ABAQUS update tool is compiled.Isight’s integration of UG and ABAQUS software is completed in turn.Finally,based on Isight,the geometric parameter integrated simulation optimization platform of ball-end milling cutter is established,which uses the instruction flow method to quickly model,fully utilizes the process automation to control the milling simulation cycle execution.Extracting the simulation data establishes the milling force and milling temperature approximation model of the ball end mill geometry parameters.According to the mathematical description of the optimization problem,based on the established approximate model,the NSGA-Ⅱ optimization algorithm is used to obtain the optimized tool geometry parameters with the minimum milling force and the lowest milling temperature.The modeling,simulation and optimization of the tool are unified under the overall platform framework,and the manual repetitive modeling work is replaced by data flow and file transfer automation between software,which improves the efficiency of simulation modeling and optimization design.It provides an effective method and idea for the optimization design of high-performance special tools.