Identify Of Cutting Force Coefficients And Detection Of Tool Wear For Ball-end Milling Based On ACIS

The machining conditions of aerospace impeller blades and other complex surfaces are varied,and the engagement region between the tool and the workpiece is complex and time-varying,and the tool wear in the machining process has an important influence on the machining.For ball-end milling machining complex curved surface contact area is difficult to obtain,and the present situation of the lack of tool wear monitoring method,this article is based on ACIS/HOOPS 3d modeling framework,c++ programming language and modular design idea,developing a three-dimensional cutting force simulation platform,based on this to achieve the cutting contact area calculation,identification of the coefficient of cutting force and tool wear monitoring.The main research contents of this paper are as follows:(1)The basic framework of the three-dimensional simulation platform with ACIS/HOOPS as the underlying modeling and display was completed.The tool scanning body was established according to the envelope theory,and the simulation process of material dynamic removal was completed by integrating local tool scanning and Boolean operation.(2)Based on the structure mechanism of intersecting graph and slice in ACIS library,the cutting contact region of workpiece and cutter was obtained,and the milling force of ball-end milling in machining sculptured surfaces was modeled.In the three-dimensional software framework,the cutting force prediction function module and the cutting coefficients equation solving function module are added.The cutting force coefficient calibration experiment was completed,and the cutting force error was verified to be less than15%.(3)According to the software development kit provided by the Heidenhain machine tool,acquire the real-time position of the machine tool and calculate the real-time feed of the tool.The function module of calculating the cutting force coefficient is realized under the working condition of sculptured surfaces machining with ball-end milling,and the steps of calibration test of cutting force coefficient are eliminated.(4)A tool monitoring method is proposed,and the relationship between the cutting force coefficient and the maximum wear of the rear tool face is summarized through experiments between a specific tool and a specific material.Through the software of simulation platform,the cutting force coefficient is calculated in the process of machining,and according to the relationship between the existing cutting force coefficient and wear,the current tool wear condition is predicted.