不等螺旋角立铣刀瞬时铣削力模型与验证

doi:10.3901/JME.2024.15.393

机械工程学报 ›› 2024, Vol. 60 ›› Issue (15): 393-406.doi: 10.3901/JME.2024.15.393

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不等螺旋角立铣刀瞬时铣削力模型与验证

施壮¹, 李长河¹, 刘德伟¹, 张彦彬¹, 秦爱国², 曹华军³, 陈云⁴

1. 青岛理工大学机械与汽车工程学院青岛 266520;
2. 青岛卡沃斯智能制造有限公司青岛 266100;
3. 重庆大学机械与运载工程学院重庆 400044;
4. 成都工具研究所有限公司成都 610500

收稿日期:2023-09-03 修回日期:2024-01-25 出版日期:2024-08-05 发布日期:2024-09-24
作者简介:施壮，男，1996年出生。主要研究方向为洁净与精密制造。E-mail：qdlg_zhuang@163.com
李长河(通信作者)，男，1966年出生，博士，教授，博士研究生导师。主要研究方向为智能与洁净精密制造。E-mail：sy_lichanghe@163.com
基金资助:
国家重点研发计划(2020YFB2010500)、山东省重大创新工程(2019JZZY020111)、泰山学者工程专项经费资助(tsqn202211179)和山东省青年科技人才托举工程(SDAST2021qt12)资助项目。

Instantaneous Milling Force Model and Verification of Unequal Helix Angle End Mill

SHI Zhuang¹, LI Changhe¹, LIU Dewei¹, ZHANG Yanbin¹, QIN Aiguo², CAO Huajun³, CHEN Yun⁴

1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520;
2. Qingdao Kaws Intelligent Manufacturing Co. Ltd., Qingdao 266100;
3. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044;
4. Chengdu Tool Research Institute Co. Ltd., Chengdu 610500

Received:2023-09-03 Revised:2024-01-25 Online:2024-08-05 Published:2024-09-24

摘要/Abstract

摘要： 随着航空航天轻量化趋势的迫切需求，铣削是框架类弱刚度零部件不可或缺的加工方法，然而铣削过程瞬时力变化导致薄壁结构件等弱刚度工件的颤振产生加工变形是其技术瓶颈。而立铣刀不等分齿间角和螺旋角已被证实是抑制颤振的有效方法。但切削力变化是诱发工艺系统颤振的本源，不等螺旋角立铣刀铣削弱刚度结构件力学行为尚未完善。基于此，建立了不等螺旋角立铣刀瞬时铣削力数学模型。首先，分析了不等螺旋角周向平面化下角度位置关系，研究了切削刃之间的轴向时变特性对任意轴向位置瞬时切削厚度的影响关系，建立了不等分齿间角微元体的力模型并轴向积分后得到单刃瞬时切削力模型。其次，分析了不等螺旋角切削刃在切削域中的参与情况，并提出了多刃同时切削时多窗口函数叠加的铣削力线性预测方法。进一步的，采用了线性回归后的斜切变换方法进行系数标定，得到了基于铣削斜变化下的系数预测方法。最后，开展了传统立铣刀与不等螺旋角立铣刀干式铣削Ti-6Al-4V验证性实验。结果表明，线性回归方法下的传统立铣刀数值解与测量值在进给方向F_y平均误差为1.17%，切削表面法向F_x平均误差为2.09%。铣削斜切变换方法下不等螺旋角立铣刀得到的F_y平均误差为0.13%，相比于线性回归方法预测精度提高了6.36%。不等螺旋角导致切削刃之间具备的轴向时变特性，是导致了力信号周期性改变，抑制颤振的根本原因。

关键词: 铣削, 钛合金, 弱刚度, 铣削力, 螺旋角, 齿间角

Abstract: With the urgent demand for lightweight trends in aerospace, milling is an indispensable processing method for weak stiffness components such as frames. However, the instantaneous force changes during the milling process lead to vibration and machining deformation of weak stiffness components such as thin-walled structural components, which is the technical bottleneck. The unequal division of pitch and helix angle for end mills has been proven to be an effective method for suppressing chatter. However, changes in cutting force are the root cause of inducing process system chatter, and the mechanical behavior of milling weak stiffness structural components with unequal helix angle end mills has not yet been improved. Based on this, a mathematical model for instantaneous milling force of unequal helix angle end mills is established. Firstly, the angle position relationship under circumferential planarization of unequal helix angles is analyzed, and the influence of axial time-varying characteristics between cutting edges on the instantaneous cutting thickness at any axial position is studied. A force model of micro elements with unequal pitch is established and integrated axially to obtain a single edge instantaneous cutting force model. Secondly, the participation of unequal helix angle cutting edges in the cutting domain is analyzed, and a linear prediction method for milling force is proposed based on the superposition of multiple window functions when multiple cutting edges are simultaneously cut. Furthermore, the oblique transformation method after linear regression is used for coefficient calibration, a coefficient prediction method based on milling oblique transformation is obtained. Finally, validation experiments are conducted on dry milling of Ti-6Al-4V using a traditional end mill and an unequal helix angle end mill. The results show that under the linear regression method, the average error between the numerical solution of the traditional end milling cutter and the measured value in the feed direction F_y is 1.17%, and the average error in the cutting surface normal direction F_x is 2.09%. The average error of F_y obtained by the unequal helix angle end milling cutter using the milling oblique transformation method is 0.13%, which improves the prediction accuracy by 6.36% compared to the linear regression method. The axial time-varying characteristics between cutting edges caused by unequal helix angles are the fundamental reason for periodic changes in force signals and suppression of chatter.

Key words: milling, titanium alloy, weak stiffness, milling force, helix angle, pitch

中图分类号:

TH161

施壮, 李长河, 刘德伟, 张彦彬, 秦爱国, 曹华军, 陈云. 不等螺旋角立铣刀瞬时铣削力模型与验证[J]. 机械工程学报, 2024, 60(15): 393-406.

SHI Zhuang, LI Changhe, LIU Dewei, ZHANG Yanbin, QIN Aiguo, CAO Huajun, CHEN Yun. Instantaneous Milling Force Model and Verification of Unequal Helix Angle End Mill[J]. Journal of Mechanical Engineering, 2024, 60(15): 393-406.

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不等螺旋角立铣刀瞬时铣削力模型与验证

Instantaneous Milling Force Model and Verification of Unequal Helix Angle End Mill

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