Design And Process Analysis Of End Milling Cutter With Gradual Spiral Angle For Typical Materials

In the process of milling,as one of the important geometric parameters of the end mill,the helix angle has a significant impact on the milling force,tool tip strength,etc.The end mill with gradual spiral angle is a kind of tool whose spiral angle gradually increases on the fixed cutting edge.The change of spiral angle can not only ensure the tool tip strength by cutting the workpiece with a small spiral angle,but also reduce the influence of the increase of axial cutting depth on the milling force by gradually increasing the spiral angle.Based on finite element simulation and milling experiments,this paper designs a tapered spiral angle end mill suitable for processing titanium alloy Ti6Al4 V and aluminum alloy Al7075-T651,two typical materials,and explores the rules of the influence of the technological parameters of tapered spiral angle end mill on the milling force based on the change of cutting layer parameters.Firstly,the changing rule of spiral of end mill with gradual spiral angle is analyzed;According to the material characteristics of the two typical materials and the requirements for the processing tools,the basic parameters of the tapered spiral angle end mill for processing the two typical materials are determined;The mathematical model of spiral curve of end mill with gradual spiral angle is established.Secondly,based on the mathematical model of helix,the three-dimensional models of conventional end milling cutter and end milling cutter with gradual spiral angle with different cutter geometric parameters are established.Combined with the finite element simulation of processing two typical materials,the influence of geometric parameters of the end milling cutter with gradual spiral angle on the milling force is analyzed,and the geometric parameters of the end milling cutter with gradual spiral angle when processing two typical materials are optimized.Then,the single factor analysis of the influence of process parameters on the milling force is carried out for the optimized tapered spiral angle end milling cutter;The influence law of spiral angle change on cutting layer parameters is explored,and the influence law of process parameters of tapered spiral angle end milling cutter on milling force is analyzed based on the change of cutting layer parameters.Finally,the gradual spiral angle end milling cutter and the conventional end milling cutter are ground and orthogonal milling experiments are carried out.Through the range analysis of the orthogonal experimental results,the primary and secondary order of the influence of the process parameters of the gradual spiral angle end milling cutter on the milling force when processing two typical materials is explored,and the optimal process parameters with the minimum average milling force are determined;Combined with the experimental results to verify the simulation model,determine the reliability and accuracy of the simulation model.