Experimental Study On The Interactive Effect Of Mesoscopic Geometric Features On The Cutting Performance Of Ball Nose Milling Cutter

In the cutting of titanium alloy materials,there are common problems such as large cutting force,low processing efficiency,and severe tool wear.However,microtextures placed on the tool surface can effectively reduce the friction in the tool-chip contact area and improve the cutting performance of the tool.In addition,the strengthening of the cutting edge has positive significance for the improvement of the performance of the cutting tool.Since the tool edge and micro-texture scale range from tens of microns to hundreds of microns,they are collectively referred to as mesoscopic geometric features.There is an interaction between different mesoscopic geometric feature parameters,thereby constraining the cutting performance of the tool and the surface quality of the workpiece.Therefore,this paper uses theoretical derivation to determine the uniform density function of the micro-texture on the rake face of the ball nose milling cutter;based on simulation and test methods,the influence of the interaction between the mesoscopic geometric features of the tool on its milling behavior and the surface quality of the workpiece is analyzed.Based on this,the following studies were carried out:Firstly,with the ball end milling cutter as the entry point,the theoretical contact length of the tool-chip is calculated based on the chip curl theory,and the theoretical contact area between the tool and the chip is obtained by combining the theoretical contact area of the tool and the workpiece.The structure is placed into the area;the uniform distribution density function is established through the theory of uniformly distributed random points in the circular area,and the generation algorithm of uniformly distributed random points is obtained,and finally the mathematical model of micro-texture distribution is established,and the theoretical knife-chip contact area and The accuracy of the distribution in the form of a uniform distribution density function.Secondly,based on the above theoretical analysis,a simulation study is carried out on the milling process of titanium alloy with cemented carbide ball end milling cutters with different mesoscopic geometric characteristic parameters;the influence of different mesoscopic geometric parameters on tool milling force and milling temperature is analyzed,and its role is revealed.The mechanism provides a basis for the verification analysis of subsequent experiments and the parameter optimization of the mesoscopic geometric feature ball nose milling cutter.Thirdly,laser processing and sandblasting are used to complete the preparation of mesoscopic geometric feature tools,and a titanium alloy milling experimental platform is built to study the influence of mesoscopic geometric feature parameters on tool average milling force,workpiece surface roughness and tool wear,and reveal its The mechanism of action is based on the evaluation criteria of milling force,surface roughness and tool wear to optimize the range of mesoscopic geometric characteristic parameters.Finally,with the average milling force,workpiece surface roughness and tool wear as evaluation indicators,the corresponding regression mathematical model was established based on multiple linear regression analysis,and the bird swarm algorithm was used to analyze the micro-pit diameter D,The distance between two adjacent micro-textures is l1,the distance from the cutting edge is l,and the radius of the blunt circular cutting edge is searched in the solution space to obtain the final optimization result.And compared with the test results to prove the reliability and accuracy of the optimization results.