Study On Process Parameters Optimization For High Efficiency Milling Of Nickel Based Superalloy Based On Cutting Simulation

With the excellent high temperature properties,Nickel-based superalloys are used widely by the core part of aerospace engine.However,the difficult machining characteristic makes the machining tool very expensive,easily abrasion and lower machining efficiency.Using traditional experimental method study milling Nickel-based superalloys processes will significantly increase the R&D cost and cycles.With the development of computer performance and finite element technology in the field of cutting,it has become a research trend to use numerical simulation method instead of experimental research.Based on the Abaqus/Explict simulation platform,solid carbide end milling cutter milling nickel-based superalloy GH4169 is studied.The details are as follows:(1)Introduced the key technology of finite element simulation of metal cutting and established a 3Dmilling numerical simulation model according to the milling processes;(2)the solid carbide end milling cutter milling nickel-based superalloy GH4169 experiments were designed and based on the same cutting parameters.At the same time 3D milling model were also built.The end milling first uses reverse engineering to perform 3D solid scanning,and then reconstructs by the point cloud in order to reduce the uncertain factors caused by tool geometry error.Finally,the cutting force is used as the index,through comparative analysis between the simulation and experiment,it shows the maximum cutting force error is about 20%,and the cutting force change trend identical.Finally the reliability of simulation model was verified;(3)Based on the verified milling simulation model,the orthogonal experiment of process parameter optimization for high-efficiency milling of GH4169 was designed.Using the minimum cutting force and cutting temperature as the evaluation index,and taking the material removal rate as the reference,the optimal scheme of high efficiency milling cutting dosage was finally obtained;(4)According to the manufacturing process of the vertical milling cutter,a milling cutter model based on the mathematical model of the front knife surface of the grinding wheel was established,and a single factor test of the helical angle and the rake of the end milling cutter was established respectively.The test results showed that the influence law of helical angle and rake on cutting force and heat is the similar but the degree is different.The larger helical angle and smaller rake can ensure better machinability and tool strength.