CN103761386B - A kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities - Google Patents

Abstract

A kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities, belongs to cutting-tool engineering field.The present invention specifically utilizes the associate feature of High-speed Face Milling Cutter forced vibration and cutter tooth abrasional behavior, provides milling cutter forced vibration abrasional behavior recognition methods；Set up milling cutter multiple tooth forced vibration wear model, propose the abrasion of milling cutter forced vibration and the forecast of uneven wear and judge side；Control method and the design method for milling cutter of milling cutter uneven wear are proposed, solve the multiple tooth abration position of milling cutter, wear area, the design conflicts problem of wearing depth control variable, design the diameter 63mmm milling cutter that can effectively suppress No. 45 steel knife tooth forced vibration abrasion inhomogeneities of high-speed cutting.The present invention is in Design Milling.

Description

A kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities

Technical field

The present invention proposes a kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities, specifically utilizes High-speed Face Milling Cutter forced vibration and the associate feature of cutter tooth abrasional behavior, provide milling cutter forced vibration abrasional behavior recognition methods； Set up milling cutter multiple tooth forced vibration wear model, propose the abrasion of milling cutter forced vibration and the forecast of uneven wear and judge side； Propose control method and the design method for milling cutter of milling cutter uneven wear, solve the multiple tooth abration position of milling cutter, wear area, abrasion The design conflicts problem of severity control variable, designs and can effectively suppress No. 45 steel knife tooth forced vibration abrasion inequalities of high-speed cutting The diameter 63mmm milling cutter of even property.

Background technology

In milling cutter working angles, tool wear is one of key factor affecting working angles.In actual processing, cutter grinds Damage acutely, vibration cutting is obvious, machined surface is of low quality, tool failure is serious, cutter service efficiency and under service life Degradation problem is commonplace.This seriously adds the uncertainty that milling cutter lost efficacy, and constrains the safety and efficiently of milling cutter Milling application in important spare part processing and other fields.

Different from common milling, the cutting parameter that high-efficient milling uses is the biggest, and the consequence thus brought is cutter Rapidly, even easily there is micro-tipping, damaged situation in tool abrasion.The safety of workman is had the biggest with the raising of working (machining) efficiency Impact.The decline of milling cutter safety simultaneously also results in tooling system and is deformed, and causes the change of chip-load, to adding working medium Amount, cutter life and machine tool accuracy have a direct impact.

Affected by workpiece hardness, improve stock-removing efficiency and easily cause the impact in working angles to increase with vibration, cause milling Cutter abrasion aggravation.In high-speed machining process, tool wear behavior is the result of multifactor functioning.With this understanding, carry out greatly Type Surfaces for High Speed, high-efficient cutting are processed, and its consequence is milling cutter extended active duty, and security reliability declines rapidly, do not simply fail to ensure Machining accuracy and machined surface quality, and directly result in milling cutter and lost efficacy, cause multiple safety issue, there are some researches show, With at a high speed, fierce friction and the tool wear that produces, its form and formation mechenism not only with friction pair chemistry, physics, machinery Performance is correlated with, and closely related with the friction pair change that vibration causes.

According to " CXK5463 water chamber head dedicated numerical control movable gantry milling-lathe machining center " is carried out detailed investigation it After, finding that the fretting wear of cutter can largely cause the surface processed undesirable, especially milling cutter was cutting It is obvious that the vibration produced in journey can have a strong impact on the surface processed, even chatter mark, does not reaches processing request at all, or leads Cause the great number of issues such as precise decreasing during lathe uses, and on-the-spot tool wear acutely, stop cutter tool changing situation and highlight, have Cutter even just there occurs the situations such as tipping abrasion condition is the most serious when.Seriously delay the process-cycle, restriction The service efficiency of milling cutter and service life.

At present, the domestic research about cutter fretting wear is concentrated mainly on material, above the factor such as cutting data.And The present invention considers that face milling cutters, when cutting metal material, owing to being affected with centrifugal force by cutting force, produce forced vibration；First First pass through two kinds of influencing mechanism of experimental analysis milling cutter vibration behavior behavior uneven to cutter wear behavior and cutter wear, from Controlling vibration behavior to start with, the wear problem for single cutter tooth effectively controls with cutter wear non-uniformity problem, Rather than extend cutter life with reduction cutting data, reduction stock-removing efficiency for cost.

Studying the fretting wear problem of cutter at present, most of research worker are from cutting experiment method and finite element fraction Analysis method is studied, and the fewest for the abrasion under effect of vibration and abrasion inhomogeneities research.Not in view of stress, shake The impact of dynamic Cutter wear.Therefore, from vibration angle leave for study milling cutter wear problem, with control cutter wear, Improve working (machining) efficiency, to extend milling cutter service life be the most significant.

Summary of the invention

The present invention is directed to the abrasion of face milling cutters cutter tooth with face milling cutters overall wear inhomogeneities for solving target, it is provided that one presses down The high-speed milling cutter method for designing of cutter tooth forced vibration processed abrasion inhomogeneities.

The present invention is to solve that above-mentioned technical problem is adopted the technical scheme that:

A kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities of the present invention:

Step one, the test result of foundation milling cutter forced vibration wear test, grind with milling cutter milling cutter forced vibration behavior Damage behavior is associated analyzing, it is thus achieved that milling cutter forced vibration behavior and the associate feature of cutter wear behavior；Analyze facing cut Tool wear behavior during Tool in Milling metal material；Below contrast different parameters, the cutting of milling tool processing different materials is special Property, the impact of opposite milling cutter abrasion；Propose the recognition methods of milling cutter forced vibration abrasion；

Step 2, foundation vibration are theoretical, analyze milling cutter vibration behavior in milling process, and have carried out parametrization Characterize；Analyze the feature of several main abrasion modality during face milling cutters milling metal material, and each abrasion modality occurs Position, and the abrasion modality of face milling cutters is carried out parametrization sign；Illustrate three kinds of milling cutter forced vibration behaviors to milling cutter monodentate The influencing mechanism of abrasional behavior；Analyze the forced vibration behavior impact on cutter wear behavior；Based on face milling cutters machining mistake Abrasion in journey, failure theory, analyze the shadow to cutter wear such as cutting speed, vibration cutting and cutting force in working angles Ring, disclose three kinds of milling cutter forced vibrations influencing mechanism to cutter wear inhomogeneities；Set up milling cutter multiple tooth forced vibration mill Damage model, propose the abrasion of milling cutter forced vibration and the forecast of uneven wear and evaluation method, it determines friction pair character, classification；

Step 3, according to above-mentioned six kinds of influencing mechanism, different mechanism control methods is different, it is proposed that milling cutter forced vibration The control method of abrasion inhomogeneities, discloses the milling cutter forced vibration behavior impact on cutter wear behavior, it is achieved to facing cut Effective control of cutter forced vibration abrasion；

Step 4, according to milling cutter model analysis and vibration abrasion experimental result, the accuracy of checking milling cutter control method, solve The certainly collision of variables problem in control method, solves to control loop, uses this control method, by cutter parameters, cutting parameter Design, propose milling cutter method for designing, use experiment mode verify the feasibility of method for designing, accuracy.

Preferred: the recognition methods of milling cutter forced vibration abrasion

The forced vibration of milling cutter can cause milling cutter tooth to produce forced vibration abrasion, including milling cutter forced vibration to milling cutter cutter Odontotripsis character (being rake wear or wear of the tool flank or cutting edge abrasion), abration position p(i.e. wear and tear depth capacity position Put), the degree of wear (the i.e. impact of abrasion width b and wearing depth h).Milling cutter forced vibration causes the multiple cutter tooth of milling cutter to occur not Uniform wear behavior, including three kinds of milling cutter uneven wear Forming Mechanism: milling cutter each odontotripsis character is different, abration position is uneven Even, the degree of wear is uneven.

For specifically studying and characterize the forced vibration abrasion of milling cutter intuitively, use the mode of experiment to milling cutter in work herein Abrasion under process system forced vibration measures.It is Dalian VDL-1000E lathe that experimental facilities uses, to 63mm diameter 4 tooth On tooth pitch F2033.022.040.063 milling cutter, in the workpiece fabrication of No. 45 Steel materials of cutting, vibration cutting uses east China to survey system System and PCB vibration acceleration sensor measure, the test instrunment of tool wear be KEYENCE-VHX600 type surpass the depth of field show Micro mirror.For understanding the mutual relation between forced vibration and tool wear, utilize gray system theory modeling software, Milling Parameters For: milling cutter feed engagement f_z=0.08～0.15mm/z, cutting linear velocity v_c=435～614m/min, cutting-in a_p=0.3～ 0.5mm, carries out grey correlation analysis to the vibration cutting under above parameter and abrasion.The abrasion width of forward and backward cutter is uneven Spending in close relations with milling cutter Oscillation Amplitude, forward and backward knife face wearing depth unevenness is in close relations with milling cutter frequency of vibration, and this is Owing to cutter and Workpiece vibration all present periodically, when milling cutter frequency of vibration is different from the rotation of milling cutter tooth cutting frequency, The each cutter tooth of milling cutter amplitude of milling cutter when cutting is the most different, and the forced vibration abrasion causing milling cutter is uneven wear.

Utilize face milling cutters forced vibration and cutter tooth abrasion and the associate feature of abrasion inhomogeneities, form milling cutter forced vibration The physical relationship of cutter wear behavior is mapped by behavior, can recognize that milling cutter forced vibration behavioral parameters, cutter wear behavior ginseng Number, the behavioral parameters of milling cutter uneven wear；Milling cutter forced vibration behavior affects relation to three kinds of milling cutter tooth abrasional behavior； Milling cutter forced vibration behavior affects relation to three kinds of milling cutter uneven wear behavior；Milling cutter monodentate abrasional behavior and milling cutter are uneven The forced vibration control variable of even abrasional behavior.Obtain milling cutter forced vibration behavior the physical relationship of abrasional behavior is mapped, Can be by the observation to vibration behavior, it is achieved the identification of opposite cutter wear behavior in milling process.

Preferred: milling cutter multiple tooth forced vibration abrasion forecasting method

The description of complete high-speed milling vibration signal, characterizes respectively from the three of dynamic behavior directions: line-spacing direction is moved Mechanical behavior；Direction of feed dynamic behavior；Axial direction dynamic behavior.Including three direction main frequency of vibration sizes and vibration The amplitude that dominant frequency is corresponding.

Milling cutter entirety forced vibration can change milling cutter position of tool tip and change, and changes contacting of cutter tooth and workpiece simultaneously Relation, the actual cut angle of cutter, parameter of cutting layer, wear and tear to cutter tooth with cutter tooth position relationship for research milling cutter forced vibration Impact, with the round heart of cutter tooth centre bore as zero, direction of feed as X-axis, line-spacing direction as Y-axis, major axes orientation is as Z axis Set up Descartes's rectangular coordinate system.Milling cutter at a time cutter tooth i participates in cutting, and now milling cutter vibration displacement is S_Vibration, be equivalent to Milling cutter is rocked to dotted line position, cutter tooth i at this moment position of tool tip by J_iTo J '_i.If cutter hub screwed hole radius is r spiral shell, point width Cutter hub screwed hole center of circle distance is l_Blade, the mismachining tolerance of blade i is Δ 1_i, blade rigging error on this cutter is Δ 2_i, Then position of tool tip J before vibration_iCoordinate is:

If milling cutter vibration displacement is S vibration is θ with X-axis angle_ix, and Y-axis angle be θ_iy, and Z axis angle be θ_iz, milling cutter Position of tool tip J ' after vibration_iCoordinate is:

Set up cutter and absorption surface geometric model herein, analyze actual cut length and the cutting face of Tool in Cutting sword Relation between Ji, in Milling Process, a length of main cutting edge of actual cut (line segment OA) of cutter blade and front cutting edge (line Section EB) and line segment OE sum, it is not only relevant with tool cutting edge angle and auxiliary angle, goes back and cutting parameter (feed engagement f_zWith cut Cut degree of depth a_p) relevant.

k_rFor tool cutting edge angle, k '_rFor auxiliary angle, work as f_z>a_p(cotk_r+cotk’_r) time, the actual cut length of blade and feeding Measure unrelated, it is generally the case that f_z<a_p(cotk_r+cotk’_r), here, we only analyze latter situation, pass through geometrical analysis It is readily available main cutting edge length l participating in cutting_OAWith front cutting edge length l_OBExpression formula:

$\left\{\begin{array}{c}{l}_{\mathrm{OA}}=\frac{a_p}{\sin k_r}\\ l_{\mathrm{OB}}=\frac{f_z}{(\cot k_r+\cot k_r^{\&prime;})\sin k_r^{\&prime;}}\end{array}\right.---\left(4\right)$

With point of a knife as initial point, direction of feed is X-axis, and line-spacing direction is Y-axis, and major axes orientation is that Z axis sets up cartesian coordinate System, sets up milling cutter cutting vibration and tool cutting edge angle correlation model.The displacement that milling cutter tooth is produced by vibrating is S_Vibration, be equivalent to cutter Tooth swings θ angle from initial position, and tool cutting edge angle is by k_rBecome k_r1, θ_S1For S_VibrationWith the angle of Y-axis in YOZ plane, then by three Angle function relation can obtain:

k_r1=k_r+2θ_S1 (5)

In like manner, milling cutter anterior angle γ₀, relief angle α₀In XOZ plane, cutter tooth swings θ from initial position₁Angle, anterior angle is by γ₀ Become γ₀₁, relief angle is by α₀Become α₀₁, cutting edge inclination is by λ_sBecome λ_s1, θ_S2For S_VibrationWith the angle of X-axis in YOZ plane, θ_S3For S_VibrationWith the angle of Y-axis in XOY plane, then can be obtained by trigonometric function relation:

$\left\{\begin{array}{c}{\mathrm{\&gamma;}}_{01}={\mathrm{\&gamma;}}_0+{2\mathrm{\&theta;}}_{S2}\\ {\mathrm{\&alpha;}}_{01}={\mathrm{\&alpha;}}_0-{2\mathrm{\&theta;}}_{S2}\\ {\mathrm{\&lambda;}}_{s1}={\mathrm{\&lambda;}}_s+{2\mathrm{\&theta;}}_{S3}\end{array}\right.---\left(6\right)$

Face milling cutters when milling, cutting parameter and parameter of cutting layer: feed-speed is V_f(m/min), f_ziFor arbitrarily Adjacent two between cog feed engagements (mm/z), there is phase angle in milling cutter(i is that cutter tooth code name is from 1 to Z).

Owing to milling cutter tool work piece in milling process all exists vibration, through cutting time t, when milling cutter shook in this moment Dynamic frequency is f_iTime, after milling cutter, knife face and the work piece contact point vibration abrasion degree of depth are h_After, the amplitude of cutter and workpiece is respectively For A_Cutter、A_Workpiece, then:

Tool wear position is with position of tool tip as initial point, is X-axis along main cutting edge direction, rake face normal direction opposite direction For Z axis, setting up rectangular coordinate system, making P point coordinates is (x_p, y_p, z_p), therefore, P point away from point of a knife distance is:

$l_P=\sqrt{x_p^2+y_p^2+z_p^2}---\left(9\right)$

The position of tool wear is different, and the abrasive nature representing cutter is different, when P point is positioned at rake face and has away from cutting edge One segment distance, then be crescent hollow abrasion, is wear of the tool flank when being positioned at rear knife face, if occurring on the cutting edge, is micro-tipping.

Milling cutter vibrometer reveals the vibration characteristics combined by low-frequency vibration and dither, this vibration characteristics of milling cutter Make between itself and work piece close contact surface, to produce little amplitude to move back and forth, and in single cutter tooth working angles, contact boundary The chance that face does not expose, abrasive particle is difficult to escape out friction surface.Therefore, in single cutter tooth working angles, milling cutter is with processed Do not only have unidirectional sliding frictional wear between part contact surface, and exist under adhesive wear and abrasive wear mixing mechanism effect Vibration abrasion.Milling cutter vibration and vibration abrasion model thereof in cutter tooth working angles.

Through cutting time t, when milling cutter is f at the i-th moment frequency of vibration_iTime, after milling cutter, knife face contacts with work piece After some vibration abrasion change in depth Δ h, before rake wear change width Δ b, before rake wear change in depth Δ h, cutting-in From a_pBecome a '_p, feed engagement is by f_zBecome f '_z, cutter is respectively vector S cutter, S workpiece, then with the vibration displacement of workpiece This moment milling cutter forced vibration behavioral parameters with milling cutter monodentate abrasional behavior parameters relationship is:

When bigger cutting force produces strong forced vibration, when making milling cutter vibration produce multiple frequency multiplication, the cutter wear degree of depth To increase exponentially.With this understanding, cutter wear amount constantly increased with the cutting time, and the abrasion from milling cutter vibration will make milling cutter Under completely reserved stress effect, bigger vibration abrasion is caused with work piece contact interface.Milling cutter frequency of vibration f_iDetermine The degree of depth of milling cutter vibration abrasion, and milling cutter frequency of vibration f_iBeing to be n by milling cutter rotating speed, the number of teeth is Z, and the wheel of milling cutter tooth Change cutting frequency f₃Being determined, therefore, milling cutter rotating speed is n, and the number of teeth is Z, and rotation cutting frequency f of milling cutter tooth₃It it is milling The basic controlling variable of cutter forced vibration abrasion.

Through identical cutting time t, the state of wear of each tooth of milling cutter differs, and sets up this moment adjacent two cutters tooth and cut Milling cutter multiple tooth vibration abrasion model in journey.

Feed-speed is V_f(m/min), f_ziFor arbitrary neighborhood two between cog feed engagement (mm/z), then:

Owing to vibration has directivity, and the frequency of vibration in each direction there are differences with amplitude, acts on each cutter tooth On vibration the most different, the vibration abrasion causing each cutter tooth different is different, produce cutter wear uneven.When i-th The abrasion unevenness carved is as follows:

The influence factor worn and torn milling cutter forced vibration by computation model is analyzed, and then forecast milling cutter monodentate abrasion Degree, character, position and many odontotripsises unevenness.By the analysis of forced vibration wear model multiple tooth to milling cutter milling cutter, Illustrate the spindle vibration amplitude influencing mechanism to cutter wear width in milling cutter forced vibration；In milling cutter forced vibration, main shaft shakes The dynamic amplitude influencing mechanism to milling cutter front and rear knife face abration position；In milling cutter forced vibration, spindle vibration frequency is deep to cutter wear The influencing mechanism of degree；Illustrate spindle vibration amplitude in milling cutter forced vibration and cutter wear width inhomogeneities affected machine System；The spindle vibration amplitude influencing mechanism to milling cutter front and rear knife face abration position inhomogeneities in milling cutter forced vibration；Milling cutter is subject to Compel the spindle vibration frequency influencing mechanism to cutter wear degree of depth inhomogeneities in vibration.Disclose milling cutter forced vibration be due to Change the contact relation of milling cutter and workpiece, cause the stress intensity of milling cutter and distribution to change so that the mill of milling cutter tooth Damage width, wearing depth, abration position change；Cause milling cutter vibration to there is phase contrast owing to the cutter tooth of milling cutter is distributed, make Obtain milling cutter body vibration and be applied to the vibration displacement difference of each cutter tooth of milling cutter local, therefore, form the many odontotripsises of milling cutter not Uniformly.

Preferred: milling cutter multiple tooth forced vibration Wear evaluation method

First, calculated by forced vibration wear test result: wear and tear at milling cutter rake face, rear knife face, cutting edge three Abration position unevenness, abrasion width unevenness, wearing depth unevenness, contrast obtain three kinds of unevenness maximums Value, i.e. l_{(AD) max}、b_{(AD) max}、h_{(AD) max}Which all occur in position.Contact stress relation between milling cutter and friction of workpiece pair is:

$\mathrm{\&sigma;}=\frac{F_c}{S}=\frac{{\mathrm{ka}}_e^p{f}_z^q{a}_p{\mathrm{Zd}}^r{n}^m}{S}---\left(15\right)$

In formula: σ is that milling cutter contacts compressive stress, F with friction of workpiece pair_cFor cutting force, S is cutter wear area, a_eFor milling Width, k, p, q, r, m are respectively coefficient, different materials are determined.

The abration position of milling cutter directly determines the abrasive nature of milling cutter, it is considered to during milling cutter uneven wear, same milling The different cutter tooth abration positions of cutter and wear area together decide on the friction pair character that milling cutter is formed, each wear area with workpiece Under abrasive nature be intended to, therefore, it can whether exist according to the produced wear area of two cutters tooth abrasion comprise pass The character being the abrasion of decision content cutter tooth is the most consistent, it may be assumed that

$\frac{1}{2}{S}_i\&Subset;S_j---\left(18\right)$

In formula: i is less i-th tooth of wear area, j is wear area bigger jth tooth.If formula 18 is false, two cutters tooth Abration position uneven, now should first adjust parameter so that abration position is identical.

If formula 18 is set up, analyze friction pair type.When contact stress is more than yield strength [σ_s] time, milling cutter weares and teares, Thus set up wear area criterion:

$\left\{\begin{array}{c}{S}_1<\frac{F_{c1}}{\left[{\mathrm{\&sigma;}}_s\right]}\\ S_2\&GreaterEqual;\frac{F_{c2}}{\left[{\mathrm{\&sigma;}}_s\right]}\end{array}\right.---\left(16\right)$

This formula reflects the type of two kinds of friction pairs；Work as S₁During establishment, friction pair contact area is little, and wear area can shaken Change along with the continuation of working angles under conditions of Dong；Work as S₂During establishment, friction pair contact area is big, wearing depth meeting Change along with the continuation of working angles under conditions of vibration.

Work as S_i、S_jDo not belong simultaneously to S₁Or S₂Time, the friction pair type of two cutters tooth is different, now should first adjust parameter, make Obtain friction pair type identical.

Work as S_i、S_jBelong to S₁Or S₂Time, it is considered to the cutter wear degree of depth.And in the initial stage of milling cutter forced vibration abrasion, The tool surface of new sharpening is coarse, and microfissure, oxidation or decarburized layer defect, therefore the time in this stage is shorter, abrasion , it is considered to whether the increase of wearing depth can cause the change of wear area S, and then affect friction pair and connect comparatively fast, on this basis The stability of the state of touching.Therefore, the degree of depth of milling cutter forced vibration abrasion should meet:

$\left\{\begin{array}{c}{h}_i\&le;h_{\max }\\ h_i=h_j\end{array}\right.---\left(17\right)$

In formula: abrasion depth capacity h_maxBeing 0.05～0.10mm, the size of wear extent is relevant with grinding quality.

Preferred: tool wear inhomogeneities control method

Utilize the above-mentioned single factor test analyzed on the abrasion of milling cutter forced vibration and the impact of abrasion inhomogeneities, control Dan Yin Element, it is achieved to the abrasion of face milling cutters forced vibration and the control of abrasion inhomogeneities.Design variable is provided for Tool Design.Due to milling There is phase angle in cutter(i is that cutter tooth code name is from 1 to Z), the amplitude of each cutter tooth of milling cutter is different, connects with workpiece with i-th cutter tooth On the basis of when touching, the speed of mainshaft is n, if master blade amplitude is A_i(t), then adjacent i+1 tooth amplitude is:

In milling process, under centrifugal force encourages with cutting force, when cutting force becomes big, cutter can produce strong being forced to Vibration, meanwhile, workpiece there is also vibration in milling process；

Setting milling cutter rotating speed as n, the number of teeth is Z, and frequency of vibration is f₁；Feed-speed is V_f, frequency of vibration is f₂, because of This, wait rotation cutting frequency f of tooth pitch milling cutter tooth₃, the spacing frequency that the most adjacent two cutters tooth participate in cutting is:

f₃=nZ (20)

Owing to cutter and Workpiece vibration all present periodically, when milling cutter frequency of vibration is f₁Rotation with milling cutter tooth is cut Frequency f₃Time identical, the forced vibration abrasion of milling cutter is uniform wear；Work as f₁≠f₃Time, each cutter tooth of milling cutter is milling cutter when cutting Amplitude the most different, cause milling cutter produce forced vibration uneven wear；

Milling cutter frequency of vibration f_iDetermine the degree of depth of milling cutter vibration abrasion, and milling cutter frequency of vibration f_iIt is to be by milling cutter rotating speed N, the number of teeth is Z, and rotation cutting frequency f of milling cutter tooth₃Being determined, therefore, milling cutter rotating speed is n, and the number of teeth is Z, and Rotation cutting frequency f of milling cutter tooth₃It it is the basic controlling variable of milling cutter forced vibration abrasion；

Tool in Cutting vibration behavioral parameters is decomposed with milling cutter tooth abrasional behavior parameter, cutting parameter design is become Measure the influence degree to the abrasion of milling cutter tooth forced vibration and carry out descending sequence, i.e. design sequence；Set with cutter parameters Meter variable forced vibration out of contior to cutting parameter abrasion compensates design.

Preferred: milling cutter construction designs

First, by setting up the milling cutter model of the different number of teeth, by finite element modal analysis, the vibration studying its structure is special Property, analyze the different number of teeth impact on milling vibration.For reducing vibration cutting, improving crudy offer reference and foundation.Logical Cross UG set up diameter 63mm, the different number of teeth etc. tooth milling cutter physical model, tooth pitch, the 4 tooth unequal blade spacing milling cutters such as respectively 4 teeth.

Ansys boundary condition defines: cutter axially and radially there is play or can not be beated, and can not have vertically With rotation radially, so being necessary for limiting all degree of freedom of handle of a knife, here it is the constraints of cutter.Actual according to milling cutter Clamping situation, retrains the axial displacement of milling cutter shank, shank cylindrical radial direction and tangential displacement.Difference number of teeth milling when analyzing the most loaded Cutter 1～6 rank natural frequency is as shown in table 4.

The different number of teeth milling cutter natural frequency (unit: Hz) of table 4

Table 4 understands, and 4 teeth do not wait the tooth milling cutters such as six first order mode ratios of tooth milling cutter little.Under the identical number of teeth, natural frequency connects very much Closely, it is mode compact district；Natural frequency difference is bigger；Second order and three rank natural frequencies differ greatly, for mode rarefaction.In tooth Away from, the variation tendency of its natural frequency is all in descending change.The natural frequency of cutter is had by the tooth pitch of this explanation cutter Impact, when the natural frequency of cutter is close to the excited frequency of system of processing, it is possible to cause the resonance of cutter, the sending out of tremor Raw, i.e. multitoothed cutter easily vibrates when high-speed milling.

Preferred: milling cutter construction design is carried out experimental verification

For verifying above-mentioned analysis result further, four teeth developed are used not wait tooth milling cutter: a diameter of 63mm, tooth pitch is respectively It is 88,89,91,92, carries out No. 45 steel experiments of high-speed milling with the flank of tooth milling cutter such as diameter 63mm tetra-tooth, test its vibration characteristics: Experiment lathe, workpiece, cutter and experiment parameter are as shown in table 5:

Table 5 confirmatory experiment parameter

Utilizing VDL-1000E lathe, measure spindle vibration, cutter tooth abrasion, measurement result is as shown in table 6, wherein: X be line-spacing direction, Y for axially, Z be direction of feed.

The teeth such as table 6 four tooth vibrate and abrasion unevenness Comparative result with not waiting experiment of tooth milling cutter

When the change of cutter parameters Yu cutting parameter, the forced vibration of milling cutter occurs to change, wherein, and cutter tooth, tool angle Degree, tooth pitch are the design variables of cutter；Determine the vibration of this cutter, be also the control causing the abrasion change of milling cutter forced vibration simultaneously Factor processed, from experimental result it can be seen that its forced vibration and forced vibration abrasion have improvement, four teeth designed are not On tooth milling cutter: structure of the cutter body is taper cutter hub, cutter hub material is 40Cr, and trip bolt uses fine thread screw, trip bolt material Material is 35CrMo, and blade is TiN coated cemented carbide insert；Milling cutter diameter d is 63mm, and cutter Mold processing L is 36mm, cutter teeth Number is 4 teeth, and tool cutting edge angle is 45 °；Anterior angle γ installed by blade₀Being 2 °, cutter tooth distribution uses and does not waits tooth distribution, and cutter tooth progressive error is 5 °, a diameter of 63mm, between cog angle is 88,89,91,92；This milling cutter changes shaking of milling cutter tooth by changing cutter tooth distribution Dynamic frequency, reduces the abrasion of milling cutter tooth；Meanwhile, by this cutter teeth away from the adjustment being distributed phase angle so that milling cutter Milling frequency consistent with the frequency of vibration of milling cutter, reduce milling cutter forced vibration abrasion inhomogeneities, therefore can pass through Changing cutter parameters to be designed milling cutter, forced vibration and forced vibration to milling cutter wear and tear and abrasion inhomogeneities has Effect, then by changing cutting parameter, while reaching the milling efficiency of processing request, do not change character and the mill of abrasion Damage speed, finally make milling cutter realize the target of high life.

The present invention compared with prior art has the effect that

In face milling cutters milling process, there are three kinds of typical abrasion modality in cutter tooth abrasion: rake wear, rear knife face grind Damage and wear and tear with cutting edge.In high-speed machining process, tool wear behavior is the result of multifactor functioning.Control variable is main It is: cutter parameters and cutting parameter；Experimental analysis shows, with at a high speed, fierce friction and the tool wear that produces, its form and Formation mechenism is not only relevant to friction pair chemistry, physics, mechanical performance, and the friction pair change caused with abrasion and forced vibration Change closely related.

Cutter wear inhomogeneities is not only relevant with the degree of wear of each cutter tooth of milling cutter, shape of also wearing and tearing with each cutter tooth The position that state, abrasion occur is relevant；Certain contact is there is, vibration between several tool wear forms observed from experiment Abrasion can cause the degree of wear of certain abrasion modality to change, and when the degree of wear changes to a certain degree, wear and tear shape State changes.

Realize to cutter tooth abrasion control, must start with by tribology and vibration both direction, analysis and Control change Measure and milling cutter tooth abrasion and the impact of cutter wear inhomogeneities and control variable are caused cutter to the impact of forced vibration Abrasional behavior changes with abrasion inhomogeneities.From the angle of cutter structure, by milling cutter is vibrated Behavior-Based control, control milling Cutter forced vibration weares and teares, and defines the control method of effective milling cutter forced vibration abrasion, has delayed cutter life.Final proposition A kind of method for designing of high life milling cutter.Have devised four teeth and do not wait tooth milling cutter: a diameter of 63mm, tooth pitch is respectively 88,89,91,92, this milling cutter reduces the abrasion of milling cutter tooth and the inhomogeneities of milling cutter forced vibration abrasion.

Outside existing milling cutter vibration abrasion research is for the main consideration cutting parameter etc. of the factor that affects milling cutter vibration abrasion In factor, with reduce milling cutter vibrate as means, reach to suppress the effect of the abrasion of single cutter tooth.Adopt and have three in this way Individual aspect problem: although one is the wear problem solving single cutter tooth, but do not account for multiple cutter tooth abrasion inhomogeneities Problem, have ignored milling cutter multiple cutter tooth abrasion uneven cause the milling cutter life-span decline problem；Two be this method be with reduce cut Cut parameter, to reduce what production efficiency was worn and torn for the cost single cutter tooth of suppression, but the collaborative control of multiple cutter tooth abrasion can not be realized System；Three is cannot to solve cutter tooth abrasion inhomogeneities that machine vibration causes and milling cutter declines problem service life.

This invention is for the purpose of solution milling cutter forced vibration causes many odontotripsises non-uniformity problem, it is proposed that impact is many The milling cutter vibration Activity recognition method of odontotripsis, discloses the forced vibration control variable of the many odontotripsises of milling cutter.

Establish milling cutter forced vibration wear model, illustrate milling cutter construction, error, cutting parameter, vibration behavioral parameters with Relation between cutter tooth abrasional behavior, it is achieved that to each cutter tooth abration position of milling cutter, wear area, the forecast of wearing depth and Effectively control, solve the collision problem of milling cutter stock-removing efficiency and milling cutter life-span.

The milling cutter multiple tooth forced vibration abrasion inhomogeneities control method proposed and design method for milling cutter, utilize milling cutter Tooth pitch distribution can change its forced vibration behavioral trait, regulation and control lathe and milling cutter vibration to be affected cutter tooth abrasion inhomogeneities, solves Certainly cutter tooth abrasion inhomogeneities and milling cutter decline problem service life.

Accompanying drawing explanation

Fig. 1 is Design Milling flow chart；Fig. 2 is milling cutter forced vibration abrasional behavior identification process figure；Fig. 3 is tool work piece Contact relation figure；Fig. 4 is milling cutter cutting vibration and tool cutting edge angle correlation model figure；Fig. 5 is milling cutter cutting parameter and parameter of cutting layer Graph of a relation；Fig. 6 is the tool wear location drawing；Fig. 7 is milling cutter monodentate vibration abrasion illustraton of model；Fig. 8 is the multiple tooth vibration abrasion of milling cutter Illustraton of model；Fig. 9 is milling cutter forced vibration Wear evaluation method flow diagram；Figure 10 is the control of milling cutter forced vibration uneven wear Flow chart；Figure 11 is the uneven behavior figure of milling cutter forced vibration；Figure 12 is the teeth such as four teeth and does not wait tooth milling cutter physical model figure； Figure 13 is that diameter 63mm tetra-tooth does not wait tooth milling cutter tooth scattergram.

Detailed description of the invention

The preferred embodiment of the present invention is elaborated below according to accompanying drawing.

A kind of high-speed milling cutter method for designing suppressing cutter tooth forced vibration abrasion inhomogeneities of present embodiment specifically walks Suddenly it is:

1. milling cutter forced vibration abrasion recognition methods

Owing to process system exists forced vibration in milling process, along with the continuation of working angles, due to cutter and work Part, cutter contact with each other with chip；Mutually moving with certain linear velocity, vibration simultaneously produces displacement, is formed a kind of with cutter The Dynamic wear process of tool working angles, i.e. the dynamic characteristic of milling cutter forced vibration.

The forced vibration of milling cutter can cause milling cutter tooth to produce forced vibration abrasion, including milling cutter forced vibration to milling cutter cutter Odontotripsis character (being rake wear or wear of the tool flank or cutting edge abrasion), abration position p(i.e. wear and tear depth capacity position Put), the degree of wear (the i.e. impact of abrasion width b and wearing depth h).Milling cutter forced vibration causes the multiple cutter tooth of milling cutter to occur not Uniform wear behavior, including three kinds of milling cutter uneven wear Forming Mechanism: milling cutter each odontotripsis character is different, abration position is uneven Even, the degree of wear is uneven.

For specifically studying and characterize the forced vibration abrasion of milling cutter intuitively, use the mode of experiment to milling cutter in work herein Abrasion under process system forced vibration measures.It is Dalian VDL-1000E lathe that experimental facilities uses, to 63mm diameter 4 tooth On tooth pitch F2033.022.040.063 milling cutter, in the workpiece fabrication of No. 45 Steel materials of cutting, vibration cutting uses east China to survey system System and PCB vibration acceleration sensor measure, the test instrunment of tool wear be KEYENCE-VHX600 type surpass the depth of field show Micro mirror.For understanding the mutual relation between forced vibration and tool wear, utilize gray system theory modeling software, Milling Parameters For: milling cutter feed engagement f_z=0.08～0.15mm/z, cutting linear velocity v_c=435～614m/min, cutting-in a_p=0.3～ 0.5mm, carries out grey correlation analysis to the vibration cutting under above parameter and abrasion.

Table 1 forced vibration and abrasional behavior parameter grey correlation analysis

According to table 1 interpretation of result: 1. rake wear width b_BeforeWith main shaft line-spacing amplitude, axis feeding amplitude relation Closely；2. rake face greatest wear degree of depth h_BeforeClose with main shaft main shaft line-spacing amplitude relation；3. rake face greatest wear degree of depth position Put the most in close relations with main shaft axial amplitude, main shaft frequency, axis feeding amplitude, the axis feeding frequency that shakes that axially shakes；4. wear of the tool flank Width b_AfterAmplitude relation axial with main shaft is close；5. knife face greatest wear degree of depth h after_AfterWith main shaft axial amplitude；6. after, knife face is Axially shake frequency, axis feeding amplitude, axis feeding of big wearing depth position and main shaft line-spacing amplitude, main shaft shakes frequently.

It addition, each cutter tooth of milling cutter affects due to cutter structure, error and machining condition, each odontotripsis is different, i.e. weares and teares Tool wear degree of irregularity: for having the cutter of multiple cutter tooth, when milling, each cutter tooth simultaneously participates in cutting, but by In vibration cutting so that cutter is different in the wear extent of different cutters tooth, the most multiple tool wear degrees of irregularity.Tool wear is not Uniformity coefficient can cause cutting stability to be deteriorated, and machined surface quality changes.Mean deviation by the wear extent of each cutter tooth The meansigma methods AD size of numerical value evaluates the degree of irregularity of multiple cutter tooth abrasion.The i-th moment rake wear degree of depth is uneven Spend as shown in Equation 1:

Utilize gray system theory modeling software, above six groups of parametric vibrations are carried out with abrasion inhomogeneities experimental result Grey correlation analysis.

Table 2 forced vibration and abrasion unevenness grey correlation analysis

According to table 2 analysis result:

1. rake wear width unevenness and main shaft line-spacing amplitude, main shaft axial amplitude, axis feeding shake frequency relation Closely；2. rake wear degree of depth unevenness and main shaft line-spacing shake frequently, main shaft axially shakes frequency, axis feeding shakes, and frequency relation is close Cutting, wherein main shaft line-spacing shakes frequency on its impact significantly；3. wear of the tool flank width unevenness is entered with main shaft line-spacing amplitude, main shaft Having relation to amplitude, wherein the impact of main shaft line-spacing amplitude is notable；4. wear of the tool flank degree of depth unevenness and main shaft line-spacing shake frequency, Main shaft axially shakes frequently, axis feeding shakes, and frequency is the most relevant, and wherein the impact of axis feeding amplitude is notable.

By above-mentioned conclusion it can be seen that the abrasion width unevenness of forward and backward cutter is in close relations with milling cutter Oscillation Amplitude, Forward and backward knife face wearing depth unevenness is in close relations with milling cutter frequency of vibration, and this is owing to cutter all presents with Workpiece vibration Periodically, when milling cutter frequency of vibration is different from the rotation of milling cutter tooth cutting frequency, each cutter tooth of milling cutter is milling cutter when cutting Amplitude the most different, cause the forced vibration abrasion of milling cutter for uneven wear.

By above-mentioned association analysis, it is thus achieved that the physical relationship of abrasional behavior is mapped by milling cutter forced vibration behavior, it is possible to By the observation to vibration behavior, it is achieved the identification to face milling cutters forced vibration abrasional behavior, (see figure 2).

Using above-mentioned recognition methods, utilize the abrasion of face milling cutters forced vibration and cutter tooth and abrasion inhomogeneities associates spy Property, forming milling cutter forced vibration behavior maps the physical relationship of cutter wear behavior, can recognize that milling cutter forced vibration behavior Parameter, cutter wear behavioral parameters, the behavioral parameters of milling cutter uneven wear；Milling cutter tooth is worn and torn by milling cutter forced vibration behavior Three kinds of behavior affect relation；Milling cutter forced vibration behavior affects relation to three kinds of milling cutter uneven wear behavior；Milling cutter list Odontotripsis behavior and the forced vibration control variable of milling cutter uneven wear behavior.

2. milling cutter multiple tooth forced vibration abrasion forecasting method

Find out from experiment, the description of complete high-speed milling vibration signal, from the three of dynamic behavior directions difference tables Levy: line-spacing directional dynamics behavior；Direction of feed dynamic behavior；Axial direction dynamic behavior.Including three direction vibrations Dominant frequency size and amplitude corresponding to main frequency of vibration.

Milling cutter entirety forced vibration can change milling cutter position of tool tip and change, and changes contacting of cutter tooth and workpiece simultaneously Relation, the actual cut angle of cutter, parameter of cutting layer, wear and tear to cutter tooth with cutter tooth position relationship for research milling cutter forced vibration Impact, with the round heart of cutter tooth centre bore as zero, direction of feed as X-axis, line-spacing direction as Y-axis, major axes orientation is as Z axis Set up Descartes's rectangular coordinate system.Milling cutter at a time cutter tooth i participates in cutting, and now milling cutter vibration displacement is S_Vibration, be equivalent to Milling cutter is rocked to dotted line position, cutter tooth i at this moment position of tool tip by J_iTo J '_i.If cutter hub screwed hole radius is r_{Spiral shell}, point width Cutter hub screwed hole center of circle distance is l_Blade, the mismachining tolerance of blade i is Δ_1i, blade rigging error on this cutter is Δ_2i, Then position of tool tip J before vibration_iCoordinate is:

If milling cutter vibration displacement is S_VibrationIt is θ with X-axis angle_ix, and Y-axis angle be θ_iy, and Z axis angle be θ_iz, milling cutter exists Position of tool tip J ' after vibration_iCoordinate is:

The cutter set up herein and absorption surface geometric model (see figure 3), the actual cut analyzing Tool in Cutting sword is long Spend the relation between the area of cut, in Milling Process, a length of main cutting edge of actual cut (line segment OA) of cutter blade and Front cutting edge (line segment EB) and line segment OE sum, it is not only relevant with tool cutting edge angle and auxiliary angle, also and cutting parameter (per tooth enters Give amount f_zWith cutting depth a_p) relevant.

k_rFor tool cutting edge angle, k '_rFor auxiliary angle, work as f_z>a_p(cotk_r+cotk’_r) time, the actual cut length of blade and feeding Measure unrelated, it is generally the case that f_z<a_p(cotk_r+cotk’_r), here, we only analyze latter situation, pass through geometrical analysis It is readily available main cutting edge length l participating in cutting_OAWith front cutting edge length l_OBExpression formula:

$\left\{\begin{array}{c}{l}_{\mathrm{OA}}=\frac{a_p}{\sin k_r}\\ l_{\mathrm{OB}}=\frac{f_z}{(\cot k_r+\cot k_r^{\&prime;})\sin k_r^{\&prime;}}\end{array}\right.---\left(4\right)$

With point of a knife as initial point, direction of feed is X-axis, and line-spacing direction is Y-axis, and major axes orientation is that Z axis sets up cartesian coordinate System, sets up milling cutter cutting vibration and tool cutting edge angle correlation model (see figure 4).

The displacement that milling cutter tooth is produced by vibrating is S_Vibration, be equivalent to cutter tooth and swing θ angle, tool cutting edge angle from initial position By k_rBecome k_r1, θ_S1For S_VibrationWith the angle of Y-axis in YOZ plane, then can be obtained by trigonometric function relation:

k_r1=k_r+2θ_S1 (5)

In like manner, milling cutter anterior angle γ₀, relief angle α₀In XOZ plane, cutter tooth swings θ from initial position₁Angle, anterior angle is by γ₀ Become γ₀₁, relief angle is by α₀Become α₀₁, cutting edge inclination is by λ_sBecome λ_s1, θ_S2For S_VibrationWith the angle of X-axis in YOZ plane, θ_S3For S_VibrationWith the angle of Y-axis in XOY plane, then can be obtained by trigonometric function relation:

$\left\{\begin{array}{c}{\mathrm{\&gamma;}}_{01}={\mathrm{\&gamma;}}_0+{2\mathrm{\&theta;}}_{S2}\\ {\mathrm{\&alpha;}}_{01}={\mathrm{\&alpha;}}_0-{2\mathrm{\&theta;}}_{S2}\\ {\mathrm{\&lambda;}}_{s1}={\mathrm{\&lambda;}}_s+{2\mathrm{\&theta;}}_{S3}\end{array}\right.---\left(6\right)$

Set up face milling cutters when milling, cutting parameter and parameter of cutting layer relational model (see figure 5).

Feed-speed is V_f(m/min), f_ziFor arbitrary neighborhood two between cog feed engagement (mm/z), there is phase in milling cutter Parallactic angle(i is that cutter tooth code name is from 1 to Z).

Owing to milling cutter tool work piece in milling process all exists vibration, through cutting time t, when milling cutter shook in this moment Dynamic frequency is f_iTime, after milling cutter, knife face and the work piece contact point vibration abrasion degree of depth are h_After, the amplitude of cutter and workpiece is respectively For A_Cutter、A_Workpiece, then:

Tool wear position is with position of tool tip as initial point, is X-axis along main cutting edge direction, rake face normal direction opposite direction For Z axis, setting up the rectangular coordinate system of (see figure 6), making P point coordinates is (x_p, y_p, z_p), therefore, P point away from point of a knife distance is:

$l_P=\sqrt{x_p^2+y_p^2+z_p^2}---\left(9\right)$

The position of tool wear is different, and the abrasive nature representing cutter is different, when P point is positioned at rake face and has away from cutting edge One segment distance, then be crescent hollow abrasion, is wear of the tool flank when being positioned at rear knife face, if occurring on the cutting edge, is micro-tipping.

Milling cutter vibrometer reveals the vibration characteristics combined by low-frequency vibration and dither, this vibration characteristics of milling cutter Make between itself and work piece close contact surface, to produce little amplitude to move back and forth, and in single cutter tooth working angles, contact boundary The chance that face does not expose, abrasive particle is difficult to escape out friction surface.Therefore, in single cutter tooth working angles, milling cutter is with processed Do not only have unidirectional sliding frictional wear between part contact surface, and exist under adhesive wear and abrasive wear mixing mechanism effect Vibration abrasion.Milling cutter vibration and vibration abrasion model (see figure 7) thereof in cutter tooth working angles:

Through cutting time t, when milling cutter is f at the i-th moment frequency of vibration_iTime, after milling cutter, knife face contacts with work piece Point vibration abrasion change in depth Δ h_After, rake wear change width Δ b_Before, rake wear change in depth Δ h_Before, cutting-in is from a_p Become a '_p, feed engagement is by f_zBecome f '_z, cutter is respectively vector S with the vibration displacement of workpiece_Cutter、S_Workpiece, then this moment milling Cutter forced vibration behavioral parameters with milling cutter monodentate abrasional behavior parameters relationship is:

When bigger cutting force produces strong forced vibration, when making milling cutter vibration produce multiple frequency multiplication, the cutter wear degree of depth To increase exponentially.With this understanding, cutter wear amount constantly increased with the cutting time, and the abrasion from milling cutter vibration will make milling cutter Under completely reserved stress effect, bigger vibration abrasion is caused with work piece contact interface.Milling cutter frequency of vibration f_iDetermine The degree of depth of milling cutter vibration abrasion, and milling cutter frequency of vibration f_iBeing to be n by milling cutter rotating speed, the number of teeth is Z, and the wheel of milling cutter tooth Change cutting frequency f₃Being determined, therefore, milling cutter rotating speed is n, and the number of teeth is Z, and rotation cutting frequency f of milling cutter tooth₃It it is milling The basic controlling variable of cutter forced vibration abrasion.

Through identical cutting time t, the state of wear of each tooth of milling cutter differs, and therefore, sets up this moment adjacent two cutters tooth Milling cutter multiple tooth vibration abrasion model (see figure 8) in working angles:

Feed-speed is V_f(m/min), f_ziFor arbitrary neighborhood two between cog feed engagement (mm/z), then:

Owing to vibration has directivity, and the frequency of vibration in each direction there are differences with amplitude, acts on each cutter tooth On vibration the most different, the vibration abrasion causing each cutter tooth different is different, produce cutter wear uneven.When i-th The abrasion unevenness carved is as follows:

The influence factor worn and torn milling cutter forced vibration by computation model is analyzed, and then forecast milling cutter monodentate abrasion Degree, character, position and many odontotripsises unevenness.By the analysis of forced vibration wear model multiple tooth to milling cutter milling cutter, Illustrate the spindle vibration amplitude influencing mechanism to cutter wear width in milling cutter forced vibration；In milling cutter forced vibration, main shaft shakes The dynamic amplitude influencing mechanism to milling cutter front and rear knife face abration position；In milling cutter forced vibration, spindle vibration frequency is deep to cutter wear The influencing mechanism of degree；Illustrate spindle vibration amplitude in milling cutter forced vibration and cutter wear width inhomogeneities affected machine System；The spindle vibration amplitude influencing mechanism to milling cutter front and rear knife face abration position inhomogeneities in milling cutter forced vibration；Milling cutter is subject to Compel the spindle vibration frequency influencing mechanism to cutter wear degree of depth inhomogeneities in vibration.Disclose milling cutter forced vibration be due to Change the contact relation of milling cutter and workpiece, cause the stress intensity of milling cutter and distribution to change so that the mill of milling cutter tooth Damage width, wearing depth, abration position change；Cause milling cutter vibration to there is phase contrast owing to the cutter tooth of milling cutter is distributed, make Obtain milling cutter body vibration and be applied to the vibration displacement difference of each cutter tooth of milling cutter local, therefore, form the many odontotripsises of milling cutter not Uniformly.

3. milling cutter multiple tooth forced vibration Wear evaluation method

Tool wear degree of irregularity can cause cutting stability to be deteriorated, and machined surface quality changes, therefore, right It is highly important that milling cutter uneven wear carries out judge.Start with from the friction pair of milling cutter with workpiece herein, analyze cutter wear Character, wear area, the degree of wear, propose the criterion of milling cutter uneven wear, specify goal of regulation and control.

First, calculated by forced vibration wear test result: wear and tear at milling cutter rake face, rear knife face, cutting edge three Abration position unevenness, abrasion width unevenness, wearing depth unevenness, contrast obtain three kinds of unevenness maximums Value, i.e. l_{(AD) max}、b_{(AD) max}、h_{(AD) max}Which all occur in position.Contact stress relation between milling cutter and friction of workpiece pair is:

$\mathrm{\&sigma;}=\frac{F_c}{S}=\frac{{\mathrm{ka}}_e^p{f}_z^q{a}_p{\mathrm{Zd}}^r{n}^m}{S}---\left(15\right)$

In formula: σ is that milling cutter contacts compressive stress, F with friction of workpiece pair_cFor cutting force, S is cutter wear area, a_eFor milling Width, k, p, q, r, m are respectively coefficient, different materials are determined.

The abration position of milling cutter directly determines the abrasive nature of milling cutter, it is considered to during milling cutter uneven wear, same milling The different cutter tooth abration positions of cutter and wear area together decide on the friction pair character that milling cutter is formed, each wear area with workpiece Under abrasive nature be intended to, therefore, it can whether exist according to the produced wear area of two cutters tooth abrasion comprise pass The character being the abrasion of decision content cutter tooth is the most consistent, it may be assumed that

$\frac{1}{2}{S}_i\&Subset;S_j---\left(18\right)$

In formula: i is less i-th tooth of wear area, j is wear area bigger jth tooth.If formula 18 is false, two cutters tooth Abration position uneven, now should first adjust parameter so that abration position is identical.

If formula 18 is set up, analyze friction pair type.When contact stress is more than yield strength [σ_s] time, milling cutter weares and teares, Thus set up wear area criterion:

$\left\{\begin{array}{c}{S}_1<\frac{F_{c1}}{\left[{\mathrm{\&sigma;}}_s\right]}\\ S_2\&GreaterEqual;\frac{F_{c2}}{\left[{\mathrm{\&sigma;}}_s\right]}\end{array}\right.---\left(16\right)$

This formula reflects the type of two kinds of friction pairs；Work as S₁During establishment, friction pair contact area is little, and wear area can shaken Change along with the continuation of working angles under conditions of Dong；Work as S₂During establishment, friction pair contact area is big, wearing depth meeting Change along with the continuation of working angles under conditions of vibration.

Work as S_i、S_jDo not belong simultaneously to S₁Or S₂Time, the friction pair type of two cutters tooth is different, now should first adjust parameter, make Obtain friction pair type identical.

Work as S_i、S_jBelong to S₁Or S₂Time, it is considered to the cutter wear degree of depth.And in the initial stage of milling cutter forced vibration abrasion, The tool surface of new sharpening is coarse, and microfissure, oxidation or decarburized layer defect, therefore the time in this stage is shorter, abrasion , it is considered to whether the increase of wearing depth can cause the change of wear area S, and then affect friction pair and connect comparatively fast, on this basis The stability of the state of touching.Therefore, the degree of depth of milling cutter forced vibration abrasion should meet:

$\left\{\begin{array}{c}{h}_i\&le;h_{\max }\\ h_i=h_j\end{array}\right.---\left(17\right)$

In formula: abrasion depth capacity h_maxBeing 0.05～0.10mm, the size of wear extent is relevant with grinding quality.

To sum up, the evaluation method (see figure 9) of milling cutter forced vibration abrasion:

4. suppress method for designing and the checking of milling cutter uneven wear

Utilize the above-mentioned single factor test analyzed on the abrasion of milling cutter forced vibration and the impact of abrasion inhomogeneities, control Dan Yin Element, it is achieved to the abrasion of face milling cutters forced vibration and the control of abrasion inhomogeneities.Control flow (see figure 10), carries for Tool Design For design variable.

Owing to milling cutter exists phase angle(i is that cutter tooth code name is from 1 to Z), the amplitude of each cutter tooth of milling cutter is different, with i-th On the basis of when individual cutter tooth and absorption surface, the speed of mainshaft is n, if master blade amplitude is A_i(t), then adjacent i+1 tooth Amplitude is:

In milling process, under centrifugal force encourages with cutting force, when cutting force becomes big, cutter can produce strong being forced to Vibration, meanwhile, workpiece there is also vibration (see Figure 11) in milling process.

Milling cutter rotating speed is n, and the number of teeth is Z, and frequency of vibration is f₁；Feed-speed is V_f, frequency of vibration is f₂.Therefore, etc. Rotation cutting frequency f of tooth pitch milling cutter tooth₃, the spacing frequency that the most adjacent two cutters tooth participate in cutting is:

f₃=nZ (20)

Owing to cutter and Workpiece vibration all present periodically, when milling cutter frequency of vibration is f₁Rotation with milling cutter tooth is cut Frequency f₃Time identical, the forced vibration abrasion of milling cutter is uniform wear.

Work as f₁≠f₃Time, each cutter tooth of milling cutter amplitude of milling cutter when cutting is the most different, causes milling cutter to produce forced vibration not Uniform wear.

Milling cutter frequency of vibration f_iDetermine the degree of depth of milling cutter vibration abrasion, and milling cutter frequency of vibration f_iIt is to be by milling cutter rotating speed N, the number of teeth is Z, and rotation cutting frequency f of milling cutter tooth₃Being determined, therefore, milling cutter rotating speed is n, and the number of teeth is Z, and Rotation cutting frequency f of milling cutter tooth₃It it is the basic controlling variable of milling cutter forced vibration abrasion.

Tool in Cutting vibration behavioral parameters is decomposed with milling cutter tooth abrasional behavior parameter, cutting parameter design is become Measure the influence degree to the abrasion of milling cutter tooth forced vibration and carry out descending sequence, i.e. design sequence；Set with cutter parameters Meter variable forced vibration out of contior to cutting parameter abrasion compensates design.

First, by setting up the milling cutter model of the different number of teeth, by finite element modal analysis, the vibration studying its structure is special Property, analyze the different number of teeth impact on milling vibration.For reducing vibration cutting, improving crudy offer reference and foundation.Logical Cross UG set up diameter 63mm, the different number of teeth etc. tooth milling cutter physical model (see Figure 12), tooth pitch, 4 teeth such as the respectively 4 teeth tooth such as not Away from milling cutter.

Material of cutting-tool is 40Cr, and its material parameter is as shown in table 3.

Table 3 material of cutting-tool parameter

Ansys boundary condition defines: cutter axially and radially there is play or can not be beated, and can not have vertically With rotation radially, so being necessary for limiting all degree of freedom of handle of a knife, here it is the constraints of cutter.Actual according to milling cutter Clamping situation, retrains the axial displacement of milling cutter shank, shank cylindrical radial direction and tangential displacement.Two milling cutter 1～6 rank time the most loaded Natural frequency, as shown in table 4.

The different number of teeth milling cutter natural frequency (unit: Hz) of table 4

As known from Table 4,4 teeth do not wait the tooth milling cutter such as six first order mode ratios of tooth milling cutter little.Under the identical number of teeth, natural frequency connects very much Closely, it is mode compact district；Natural frequency difference is bigger；Second order and three rank natural frequencies differ greatly, for mode rarefaction.In tooth Away from, the variation tendency of its natural frequency is all in descending change.The natural frequency of cutter is had by the tooth pitch of this explanation cutter Impact, when the natural frequency of cutter is close to the excited frequency of system of processing, it is possible to cause the resonance of cutter, the sending out of tremor Raw, i.e. multitoothed cutter easily vibrates when high-speed milling.

For verifying above-mentioned analysis result further, four teeth developed are used not wait tooth milling cutter: a diameter of 63mm, tooth pitch is respectively It is 88,89,91,92, carries out No. 45 steel experiments of high-speed milling with the flank of tooth milling cutter such as diameter 63mm tetra-tooth, test its vibration characteristics, High-speed milling cutter two dimensional model (see Figure 13)

Experiment lathe, workpiece, cutter and experiment parameter are as shown in table 5:

Table 5 confirmatory experiment parameter

Utilizing VDL-1000E lathe, measure spindle vibration, cutter tooth abrasion, measurement result is as shown in table 6, wherein: X be line-spacing direction, Y for axially, Z be direction of feed:

The teeth such as table 6 four tooth vibrate and abrasion unevenness Comparative result with not waiting experiment of tooth milling cutter

When the change of cutter parameters Yu cutting parameter, the forced vibration of milling cutter occurs to change, wherein, and cutter tooth, tool angle Degree, tooth pitch are the design variables of cutter；Determine the vibration of this cutter, be also the control causing the abrasion change of milling cutter forced vibration simultaneously Factor processed, from experimental result it can be seen that its forced vibration and forced vibration abrasion have with surface quality concordance changes Kind, four teeth designed do not wait tooth milling cutter: structure of the cutter body is taper cutter hub, and cutter hub material is 40Cr, and trip bolt uses thin spiral shell Stricture of vagina screw, trip bolt material is 35CrMo, and blade is TiN coated cemented carbide insert；Milling cutter diameter d is 63mm, and cutter hangs The amount of stretching L is 36mm, and the cutter number of teeth is 4 teeth, and tool cutting edge angle is 45 °；Anterior angle γ 0 installed by blade is 2 °, and cutter tooth distribution uses and do not waits tooth Distribution, cutter tooth progressive error is 5 °, a diameter of 63mm, and between cog angle is 88,89,91,92；This milling cutter changes by changing cutter tooth distribution Become the frequency of vibration of milling cutter tooth, reduce the abrasion of milling cutter tooth；Meanwhile, by this cutter teeth away from being distributed phase angle Adjustment so that the milling frequency of milling cutter is consistent with the frequency of vibration of milling cutter, reduce milling cutter forced vibration abrasion uneven Property, therefore by changing cutter parameters, milling cutter can be designed, to the forced vibration of milling cutter and forced vibration abrasion and Abrasion inhomogeneities (life-span) is the most effective, then by changing cutting parameter, while reaching the milling efficiency of processing request, no Change character and the rate of depreciation of abrasion, finally make milling cutter realize the target of high life.

Claims (4)

1. the design method for milling cutter suppressing cutter tooth forced vibration abrasion inhomogeneities, it is characterised in that described Design Milling Concretely comprising the following steps of method:

Step one, the test result of foundation milling cutter forced vibration wear test, to milling cutter forced vibration behavior and cutter wear row For being associated analyzing, it is thus achieved that milling cutter forced vibration behavior and the associate feature of cutter wear behavior；Analyze facing cut cutter Tool wear behavior during milling metal material；Below contrast different parameters, the cutting of milling cutter Milling Process different materials is special Property, the impact of opposite milling cutter abrasion；Propose the recognition methods of milling cutter forced vibration abrasion；

Step 2, foundation vibration are theoretical, analyze milling cutter vibration behavior in milling process, and have carried out parametrization table Levy；Analyze the feature of the abrasion modality of face milling cutters cutter tooth rake face and rear knife face, and the position that each abrasion modality occurs, and The abrasion modality of face milling cutters is carried out parametrization sign；Illustrate three kinds of milling cutter forced vibration behaviors shadow to cutter wear behavior Ring mechanism, wherein three kinds of milling cutter forced vibration behavior respectively main shaft line-spacing amplitudes, shake frequency；Main shaft axial amplitude, shake frequency；Main shaft Feeding amplitude, shake frequency；Analyze the forced vibration behavior impact on cutter wear behavior；Based in face milling cutters cutting process Abrasion, failure theory, analyze cutting speed, vibration cutting and the cutting force impact on cutter wear in working angles, disclose Go out milling cutter forced vibration to cutter wear and the influencing mechanism of abrasion inhomogeneities；Set up milling cutter multiple tooth forced vibration abrasion mould Type, proposes the abrasion of milling cutter forced vibration and the forecast of uneven wear and evaluation method, it determines friction pair character, classification；

Step 3, according to above-mentioned milling cutter forced vibration to cutter wear and abrasion inhomogeneities influencing mechanism, it is proposed that milling cutter The control method of forced vibration abrasion inhomogeneities, discloses the milling cutter forced vibration behavior impact on cutter wear behavior, real The now effective control to the abrasion of face milling cutters forced vibration；

Step 4, according to milling cutter model analysis and vibration abrasion experimental result, checking milling cutter forced vibration abrasion inhomogeneities control The accuracy of method processed, solves the collision of variables problem in control method, uses this control method, by cutter parameters, cutting The design of parameter, proposes the method for designing of milling cutter, uses the mode of experiment to verify the feasibility of method for designing, accuracy.

A kind of design method for milling cutter suppressing cutter tooth forced vibration abrasion inhomogeneities the most according to claim 1, it is special Levy and be: the recognition methods of milling cutter forced vibration abrasion in described step one, particularly as follows:

The forced vibration of milling cutter can cause milling cutter tooth to produce forced vibration abrasion, grinds milling cutter tooth including milling cutter forced vibration Damage character, abration position p, the impact of the degree of wear；Milling cutter forced vibration causes each cutter tooth generation uneven wear row of milling cutter For, including three kinds of milling cutter uneven wear Forming Mechanism: milling cutter each odontotripsis character is different, abration position is uneven, abrasion journey Spend uneven；

For specifically studying and characterize the forced vibration abrasion of milling cutter intuitively, use the mode of experiment that milling cutter is subject at process system The abrasion compeled under vibration measures；Experimental facilities uses Dalian VDL-1000E lathe, to tooth pitches such as 63mm diameter 4 teeth F2033.022.040.063 milling cutter, cutting No. 45 Steel materials workpiece fabrication in vibration cutting use east China test system and PCB vibration acceleration sensor measures, and the test instrunment of tool wear is that KEYENCE-VHX600 type surpasses depth-of-field microscope； For understanding the mutual relation between forced vibration and tool wear, utilizing gray system theory modeling software, Milling Parameters is: milling Cutter feed engagementf _z=0.08～0.15mm/z, cutting linear velocityv _c =435～614m/min, cutting-ina _p =0.3～0.5mm, right Vibration cutting under above parameter and abrasion carry out grey correlation analysis；The abrasion width unevenness of forward and backward cutter and milling cutter Oscillation Amplitude is in close relations, and forward and backward knife face wearing depth unevenness is in close relations with milling cutter frequency of vibration, and this is due to cutter All present periodically with Workpiece vibration, when milling cutter frequency of vibration is different from the rotation of milling cutter tooth cutting frequency, milling cutter is each Cutter tooth amplitude of milling cutter when cutting is the most different, and the forced vibration abrasion causing milling cutter is uneven wear；

Utilize face milling cutters forced vibration and cutter tooth abrasion and the associate feature of abrasion inhomogeneities, form milling cutter forced vibration behavior The physical relationship of cutter wear behavior is mapped, identifies milling cutter forced vibration behavioral parameters, cutter wear behavioral parameters, milling cutter The behavioral parameters of uneven wear；Milling cutter forced vibration behavior produces three kinds to milling cutter tooth abrasional behavior affects relation；Milling cutter Forced vibration behavior produces three kinds to milling cutter uneven wear behavior affects relation；Milling cutter monodentate abrasional behavior and milling cutter are uneven Abrasional behavior and the relation of forced vibration control variable；Obtain milling cutter forced vibration behavior the physical relationship of abrasional behavior is reflected Penetrate, by the observation to vibration behavior, it is achieved the identification of opposite cutter wear behavior in milling process.

A kind of design method for milling cutter suppressing cutter tooth forced vibration abrasion inhomogeneities the most according to claim 2, it is special Levy and be: in described step 3, the control method of milling cutter forced vibration abrasion inhomogeneities, particularly as follows:

Utilize single factor test on the abrasion of milling cutter forced vibration and the impact of abrasion inhomogeneities, control single factor test, it is achieved to face milling cutters Forced vibration abrasion and the control of abrasion inhomogeneities；Design variable is provided for Tool Design；Owing to milling cutter exists phase angleφ _i ,iFor cutter tooth code name from 1 to Z, the amplitude of each cutter tooth of milling cutter is different, with theiOn the basis of when individual cutter tooth and absorption surface, main Axle rotating speed isn1, if master blade amplitude isA _i (t), then adjacenti+ 1 tooth amplitude is:

(19)

In milling process, under centrifugal force encourages with cutting force, when cutting force becomes big, cutter can produce strong forced oscillation Dynamic, meanwhile, workpiece there is also vibration in milling process；

Set milling cutter rotating speed asn, the number of teeth is Z, and frequency of vibration isf ₁；Feed-speed isV _f , frequency of vibration isf ₂, therefore, etc. The rotation cutting frequency of tooth pitch milling cutter toothf ₃, the spacing frequency that the most adjacent two cutters tooth participate in cutting is:

(20)

Owing to cutter and Workpiece vibration all present periodically, when milling cutter frequency of vibration isf ₁Frequency is cut in rotation with milling cutter toothf ₃Time identical, the forced vibration abrasion of milling cutter is uniform wear；Whenf ₁≠ f ₃Time, each cutter tooth of milling cutter is the shaking of milling cutter when cutting Width is the most different, causes milling cutter to produce forced vibration uneven wear；

Milling cutter frequency of vibrationf _i Determine the degree of depth of milling cutter vibration abrasion, and milling cutter frequency of vibrationf _i It is to be by milling cutter rotating speedn, tooth Number is Z, and the rotation cutting frequency of milling cutter toothf ₃Being determined, therefore, milling cutter rotating speed isn, the number of teeth is Z, and milling cutter The rotation cutting frequency of cutter toothf ₃It it is the basic controlling variable of milling cutter forced vibration abrasion；

Tool in Cutting vibration behavioral parameters is decomposed with milling cutter tooth abrasional behavior parameter, by cutting parameter design variable pair The influence degree of milling cutter tooth forced vibration abrasion carries out descending sequence, i.e. design sequence；Become with cutter parameters design Measure forced vibration out of contior to cutting parameter abrasion and compensate design.

A kind of design method for milling cutter suppressing cutter tooth forced vibration abrasion inhomogeneities the most according to claim 3, it is special Levy and be: in described step 4, the method for designing of milling cutter, particularly as follows:

First, by setting up the milling cutter model of the different number of teeth, by finite element modal analysis, study the vibration characteristics of its structure, The different number of teeth impact on milling vibration of analysis, for reducing vibration cutting, improving crudy offer reference and foundation, passes through UG Set up diameter 63mm, the identical number of teeth etc. tooth milling cutter physical model, tooth pitch, the 4 tooth unequal blade spacing milling cutters such as respectively 4 teeth；

Ansys boundary condition defines: cutter axially and radially there is play or can not be beated, and can not have vertically and footpath To rotation, so being necessary for limiting all degree of freedom of handle of a knife, here it is the constraints of cutter；According to the actual clamping of milling cutter Situation, retrains the axial displacement of milling cutter shank, shank cylindrical radial direction and tangential displacement, identical number of teeth milling cutter 1 when analyzing the most loaded ～5 rank natural frequency as shown in table 4；

Table 4 identical number of teeth milling cutter natural frequency (unit: Hz)

As known from Table 4, the tooth milling cutter such as five first order mode ratios of 4 tooth unequal blade spacing milling cutters is little, and under the identical number of teeth, natural frequency connects very much Closely, it is mode compact district；Natural frequency difference is bigger；Second order and three rank natural frequencies differ greatly, and for mode rarefaction, wait tooth Away from, the variation tendency of its natural frequency is all in descending change；The natural frequency of cutter is had by the tooth pitch of this explanation cutter Impact, when the natural frequency of cutter is close to the excited frequency of system of processing, it is possible to cause the resonance of cutter, the sending out of tremor Raw, i.e. multitoothed cutter easily vibrates when high-speed milling.