Research On Design Inspection And Performance Modeling Optimization Of Ball End Mills

Our country's equipment manufacturing industry has expanded rapidly under the guidance of Industry 4.0 and the Made in China 2025 target.In the field of metal cutting,positive research results have also been achieved.If a worker wants to do a good job,he needs to sharpen his tools first!Metal cutting tools have long been known as the "teeth" of CNC machine tools,and their output has a direct impact on part processing efficiency.The emphasis of this article is on solid carbide ball end mills,which are commonly used in the metal cutting industry.This subject's study is carried out from the following perspectives:1)Theoretical evaluationAnalyze the structure of the ball end mill and create a mathematical model of the instrument,which includes a mathematical model of the ball end mill's cross-section,end edge,peripheral edge,spiral groove,and undercut mathematical model;2)Mathematical modeling and 3D parametric modelinggThe established mathematical model is used for three-dimensional parametric modeling,which provides the finite element simulation analysis of the milling output of the ball end mill,using the UG NX11.0 modeling program,based on the structural analysis of the end mill and the established mathematical model.Model for simulation3)Ball end mill grinding and inspectionAnalyze and simulate the grinding of solid carbide ball end mills,formulate the tool grinding mechanism,grind the designed ball end mills on the ANCA FX7 five-axis CNC tool grinder,and provide for subsequent tests Milling machines;4)Finite element simulation and milling experimentDetermine the tool and workpiece material properties,create an ABAQUS finite element simulation model for ball end mill milling,consider the tool rake angle,primary relief angle,and helix angle as influencing variables,create a three-element quadratic regression orthogonal rotation combined experimental table,To obtain milling force sample data,run a milling finite element simulation and actual milling experiments.5)Target optimization of milling force performance model establishmentUse multiple nonlinear regression analysis to establish a predictive model of cutter milling force with respect to angle,and optimize the milling force performance model.Use MATLAB genetic toolbox to find the smallest milling force and find the best ball end mill within the designed angle range.The excellent combination of key angles improves the cutting efficiency of the tool.The findings of this study show that there is a quantitative quadratic nonlinear function relationship between the ball end mill's milling force and the tool's main geometric angle parameters;on the other hand,the specific processing material(A17075)is dependent on the specific material tool(YG8).The rake angle,the first relief angle,and the tool's helix angle all have an optimum matching relationship.The optimum combination of the ball nose end mill rake angle 10.37°,the first relief angle 14.56°,and the helix angle 34.53° for reducing milling force by at least 0.6 percent and up to 20.3 percent is the ball nose end mill rake angle 10.37°,the first relief angle 14.56°,and the helix angle 34.53°.This study presents theoretical and functional cutting tool approaches ranging from structural design inspection to performance modeling optimization,and it can be used to design and optimize other complex cutting tools.