Abstract: The reasonable selection of high-speed cutting parameters is an obstacle in industry. The conservative cutting parameters limit the performance of high-speed machine tool and productivity. Focusing on high-speed milling process, a dynamic model of the high-speed spindle cutter system is given based on Timoshenko beam and Jones’ bearing model with consideration of centrifugal force and gyroscopic moments. Dynamic properties of the spindle-cutter system are coupled with high-speed milling process, and then the interaction mechanism between the dynamic properties of the high-speed spindle cutter system and the machining process is investigated. The characteristic equation of the closed-loop dynamic milling system is derived. Based on the above theoretical analysis, an optimization method of cutting parameters based on the model of spindle-process interaction is proposed. The proposed optimization method is applied in the machining of the front face of a helicopter gear box cover, which is made of Aluminum. The axial depth of cut and spindle speed are chosen optimally, and the machining efficiency of the lateral wall on the front face of the gear box cover is increased 275%.

Key words: Cutting parameters optimization, High-speed milling, Interaction process, Spindle, Energy fucntions, Point set surfaces, Vector fields, Surface reconstruction