Research On Mesoscopic Scale Micro-milling Process Optimization

With the rapid development of demands of human beings are increasing,and advanced manufacturing technology in the processing efficiency and processing cost and machining accuracy continuously put forward new requirements,also constantly breakthrough in the field of machining size limit,which lead to traditional processing methods have been difficult to meet people’s needs.Under this background,the micro-scale milling technology arises at the historic moment.After continuous research,micro milling technology has become one of the important technologies in micro machining,and well known with its processing complex three-dimensional contours.,and with people constantly in-depth study,Found that micro milling technology is a highly development potential research direction.Single crystal material is a new type of material,and it have a wide range of applications in the medical,electronic,and aerospace and other fields because of its superior performance,so for the single crystal materials parts performance improvement has become a key research direction of many industries.Single crystal materials only have one grain and do not have grain boundary,and with less micro defects such as dislocations and impurities,so the polycrystalline material machining theory of single crystal materials no longer apply for it.Therefore,it is necessary to study of the micro milling process of single crystal materials.The paper addresses the micro milling process of single crystal materials research,the main method of single factor experiment,supplemented by finite element analysis method,orthogonal experiment has micro milling process of milling force of single crystal materials milling temperature has been processed material surface quality were studied,the main research contents include:(1)Analysis of the micro milling is different from conventional milling,the minimum cutting thickness phenomenon,micro milling force mechanism and micro mechanism of the milling surface roughness;And single crystal material micro structure was studied,and the cutting deformation mechanism of single crystal materials.(2)Through orthogonal experiment,the analysis of the influence of cutting parameters on surface roughness of primary and secondary factors,and carry on the comparative analysis of different material,analysis the difference between the two.Through the single factor experiments,analysis of the cutting parameters,cooling method,cutter blade number and the influence of anisotropy of surface roughness are studied.(3)Three-dimensional micro milling model is established by finite element analysis,to explore the cutting parameters and the influence of the anisotropy on the milling force rules,and based on the theory of minimum cutting thickness,of different cutting edge radius of circular arc simulated,to explore the influence of different cutting edge arc radius on the milling force,and the corresponding experimental verification experiment for simulation results,the simulation results with the experimental result of the differences and relations.(4)Construct a three dimensional micro milling temperature field finite element simulation model of the nickel base single crystal superalloy micro milling simulation study on temperature field,explores the temperature distribution and cutting parameters and the influence of anisotropy of micro milling temperature regularity,and experimental verification,analysis the difference between the experiment and the simulation results and contact.