Instantaneous Cutting Energy Distribution And Evolution Characteristics Of High Efficiency Milling Cutter Tooth Under Vibration

High efficiency milling cutters are widely used in cutting titanium alloys due to their high energy efficiency,high surface processing quality,and low tool wear rates.The process of milling cutter cutting is a process of energy consumption,and the instantaneous cutting energy of cutter teeth is an important basis for evaluating the dynamic cutting performance of milling cutters.Under the influence of milling vibration,the contact relationship between the cutter and the workpiece changes at all times,resulting in changes in the magnitude and direction of the instantaneous characteristic velocity of the cutter teeth.Changes in the instantaneous cutting layer parameters cause constant changes in the instantaneous stress condition of the cutter teeth,resulting in instability in the distribution and change of the instantaneous cutting energy of the cutter teeth,which directly affects the cutting performance and surface quality of the milling cutter.Establishing a correct calculation model for instantaneous cutting energy of milling cutter teeth and revealing its distribution and evolution characteristics can provide a basis for studying milling cutter cutting efficiency,reducing energy consumption,and improving surface quality.The existing milling cutter tooth cutting energy calculation models use the average method to calculate the cutter tooth cutting energy,without considering the impact of milling vibration,cutter tooth error,and cutter tooth wear on cutting energy.They lack the distribution information of cutting energy on the cutter tooth cutting edge,and cannot reveal the distribution and evolution characteristics of cutter tooth cutting energy along the cutting edge.In response to the above issues,this paper reveals the changing characteristics of the instantaneous cutting boundary of the cutting edge of the cutter tooth based on the instantaneous contact relationship between the cutter and the workpiece under the action of milling vibration and cutter tooth error,uses the microelement method to characterize the transient posture of the main and auxiliary cutting edges of the cutter tooth under the action of wear,proposes a solution method for the instantaneous cutting speed,shear speed,and friction speed of the rear cutter face of the cutter tooth,and constructs a calculation model for the instantaneous cutting layer parameters of the cutter tooth microelement.A method for identifying the instantaneous friction boundary on the flank of a milling cutter is proposed.The instantaneous mechanical behavior of the cutter tooth microelement is revealed through a cutting layer parameter model.Combined with the kinematic behavior of the cutter tooth microelement,the instantaneous cutting energy distribution function of the cutter tooth is established.Through milling vibration experiments and thermally coupled field stress extraction results,the instantaneous cutting posture variation characteristics of the milling cutter and the cutter tooth microelement are revealed,and the instantaneous cutting velocity vector of the cutter tooth microelement during the milling cutter cutting process is obtained The distribution characteristics of shear velocity vector,cutting force vector,and shear force vector along the cutting edge,as well as the distribution characteristics of friction velocity and friction along the flank,reveal the distribution characteristics of instantaneous cutting energy of the milling cutter teeth.Study the changes of the instantaneous cutting boundary between the main and auxiliary cutting edges and the instantaneous friction boundary of the flank,reveal the instantaneous cutting behavior characteristics of the cutter tooth microelement during the cutting process,and obtain the dynamic change characteristics of cutting force energy consumption,shear force energy consumption,and friction energy consumption.A method for identifying the instantaneous cutting energy distribution and evolution characteristics of milling cutter teeth is proposed.The response characteristics of instantaneous cutting force energy consumption,instantaneous shear force energy consumption,and instantaneous friction energy consumption on the flank of milling cutter teeth to cutting parameters are studied.The maximum instantaneous cutting energy consumption and the maximum cumulative cutting energy consumption are used to identify the differences in cutting energy consumption of cutter teeth in different milling schemes.The correlation analysis results are used to characterize the consistency of friction energy consumption of cutter teeth in different cycles,And milling experiments were carried out to verify.