The Optimization Of Flank Edge's Spatial Distribution Based On The Stability Prediction Using The Homotopy Transformation Method

With the continuous development of aerospace,new energy vehicles,national defense and the other fields,some parts with key roles are set higher standards for processing efficiency and quality of surface than ever before in manufacturing industy.Most of these higher-standard parts need to be finished by flank milling.Therefore,as an effective way to remove materials,peripheral machining has become one of the most widely used production and processing methods in manufacturing industry.On the basis of guaranteeing stable performance,high-quality products can be completed more quickly and efficiently by designing high-performance cutting tools.In this connection,a more fast stability prediction method is proposed by analyzing the the flank edge's spatial structure distribution and combining with milling dynamics model in this paper.The cutter with the optimization of flank edge's spatial distribution is also studied.The researches are as follows:1?It is explored that the relationship between spatial structure of cutter edge and position of workpiece.The relationship equation between pitch angle and helix angle on each flank edge of tool is established,which is illustrated by the developing schematic diagram of circular expansion;Combining with regeneration factor,the influence of traditional cutter on regeneration chatter is compared and analyzed to non-uniform helix angle tool,which is laid the foundation of the optimization of spatial distribution with flank edge.2 ? The dynamic milling model of traditional cutter with helix angle effect is established.The dynamic model of non-uniform helix angle tool is built by dividing the axial micro-elements.Based on the feasibility of Enhanced Perturbation Homotopy Method(EMHPM)for solving nonlinear differential equations,the homotopy transformation method(HTM)for fast prediction of stability with dynamic milling system is presented in this paper,including 1st HTM and 2nd HTM.The results of theoretical comparison is shown that computational efficiency of the 1st HTM and 2nd HTM both can be improved by about 90% than previous methods.The accuracy of 2nd HTM for predicting model with non-uniform helix angle tool is verified from experiments on the milling stability.3 ? The stable lobes of traditional cutter and non-uniform helix angle tool are predicted by 2nd HTM.According to the stable lobes of different cutters,it is shown that the change of spatial helix angle has little influence with traditional cutter.The combination of different spatial helix angles has greater influence with non-uniform helix angle tool.It is optimization ways to change the combination of helix angle.The results is shown that non-uniform helix angle tool after optimization can be greatly improved the milling efficiency within given speed range by the stability lobes of two kinds of millingcutters.4?The experimental model of frame thin-walled parts is built.Based on the result of optimization with flank edge's spatial distribution,parameters are obtained from stability experiments,two stable lobes of milling-cutters are predicted to determine the optiazation milling parameters of non-uniform helix angle tool.Processing time of two kinds of milling cutters for frame thin-walled parts is caculated.The results of processing time is shown that the processing efficiency of the optiazation design of flank edge's spatial distribution with non-uniform helix angle tool is improved by about 53%.