Design And Manufacture Of Circular Milling Cutter For Titanium Alloy Processing

Titanium alloy is widely used in aerospace industry because of its high strength,good corrosion resistance and low temperature performance.Among them,titanium alloy aerospace structural parts occupy an important position in aerospace aircraft parts.However,there are more steep facets in aeronautical titanium alloy.Due to the limited geometry of ball end milling cutter,the cutting performance of this type of surface is difficult to improve.In addition,titanium alloy is a typical difficult to machine material,so there are many problems in the process of titanium alloy processing,such as low machining efficiency,serious tool wear,and difficult to guarantee the surface quality.In order to solve these problems,this paper carried out the research on the design and manufacture of circular milling cutter for titanium alloy processing.And through the titanium alloy milling test,The influence of different milling parameters on the cutting force of arc milling cutter and ball end milling cutter is compared and analyzed,and the wear law and wear mechanism of arc milling cutter and ball end milling cutter under fixed parameters are also analyzed.The research contents mainly include the following aspects:Firstly,the design and Simulation of arc milling cutter are carried out.The geometric characteristics of rotary cutting tools are analyzed.The general model of rotary surface,the model of edge line and the model of rake and relief angles of rotary tools are established by differential geometry method.And for the circular arc milling cutter geometric features.The generatrix and edge line of circular arc milling cutter are designed and studied.The geometric model and the edge line model of circular milling cutter are established.The correctness of geometric model and edge line model is verified by MATLAB simulation.Secondly,the grinding model of circular arc milling cutter is studied.The grinding process of the whole tool is analyzed.Combined with the characteristics of circular milling cutter.The mathematical model of grinding wheel is established by differential geometry.The grinding matrix of circular arc milling cutter is established by using the meshing condition of grinding wheel and work piece.The mathematical model of the front and back face of the circular milling cutter has been established.The grinding trajectory equation of circular arc milling cutter with conventional grinding wheel is derived.Then,the grinding simulation and test of circular milling cutter are carried out.Through the analysis of SAACKE five axis grinder each axis movement relationship.Based on the motion relation of SAACKE five-axis grinding machine,the postprocessing matrix was established.Combined with the derived grinding wheel position on the front and rear cutter of circular arc milling cutter.The grinding simulation of circular arc milling cutter was carried out in VERICUT.After simulation and optimization,SAACKE five-axis grinding machine was used to grind circular arc milling cutter.The dimension and Angle accuracy of the milling cutter are tested,and the passivation and coating are carried out.Finally,the experimental study on TC4 of titanium alloy with circular arc milling cutter was carried out.The results indicate that: Compare circular milling cutters with ball milling cutters.Under different milling parameters,The main cutting force of circular arc milling cutter can be reduced by 30% at most,and the amplitude fluctuation is small;The front and rear wear areas of circular milling cutters are closer to the cutting edge and are longer and narrower.And the circular arc milling cutter wear to bond wear.There are not only bond wear but also a certain degree of oxidation wear and diffusion wear,The milling distance of circular arc milling cutter is 24% longer than that of ball-end cutter before tool failure;The whole process of cutting.Compared with ball milling cutter,the circular milling cutter has better surface quality,and the processing surface has no obvious peak and valley characteristics.