CN104731013A - Quenched steel machining method for resolving conflict between cutting efficiency and machining surface quality - Google Patents
Quenched steel machining method for resolving conflict between cutting efficiency and machining surface quality Download PDFInfo
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- CN104731013A CN104731013A CN201510043173.6A CN201510043173A CN104731013A CN 104731013 A CN104731013 A CN 104731013A CN 201510043173 A CN201510043173 A CN 201510043173A CN 104731013 A CN104731013 A CN 104731013A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention relates to a quenched steel machining method for resolving the conflict between cutting efficiency and machining surface quality. An existing quenched steel high-speed milling method taking machining surface roughness as the process design goal can not effectively control the formation process of a high-speed milling machining surface, under the influences of vibration of a cutter, process conflict exists between the quenched steel cutting efficiency and machining surface quality, and the requirement of efficiently machining large precise quenched steel moulds can not be met. According to the quenched steel machining method for resolving the conflict between cutting efficiency and machining surface quality, two or four high-speed ball-end milling cutters, an experiment method disclosing the problem of the conflict between the cutting efficiency of the high-speed milling cutters and machining surface quality, a correction method for the cutting movement tracks of the high-speed milling cutters, a machining surface residue unit for reflecting the influences of overhanging amount changes and vibration of the high-speed ball-end milling cutters on appearance of the machining surface, and a quenched steel cutting process scheme for resolving the conflict between the cutting efficiency of the high-speed ball-end milling cutters and the machining surface quality are included. The machining method is used for high-speed milling of quenched steel.
Description
Technical field:
The present invention relates to a kind of job operation of high-speed milling hardened steel, being specifically related to a kind of for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality.
Background technology:
Existing take machined surface roughness as the High Speed Milling of Hardened Steels method of technological design target, and the forming process on control high-rate wireless LAN surface not yet in effect, affect by vibration cutting, hardened steel stock-removing efficiency with there is technique between machined surface quality and conflict, the demand of highly-efficient processing large-scale precision hardened steel mould cannot be met.
High speed rose cutter is a kind of typical HSC Milling Tools, is widely used in the finishing of the large-scale hardened steel die face of automobile.More than HRC55, there is larger elastic recovery in hardened steel finished surface hardness, the vibration cutting caused thus very easily causes hardened steel machined surface quality to worsen, and directly affects die life in high-speed milling.
During high-speed milling hardened steel mould, require on the one hand to reduce with great metal removal rate to account for the machine time, require low cutting vibration and high machined surface quality on the other hand.At present, in the research of High Speed Milling of Hardened Steels milled surface topography, main employing single factor test control variate method, carry out studying and modeling for affecting the significant high speed milling parameters of machined surface roughness, less Comprehensive considers that between multi-characteristicquantity quantity, reciprocation is on the impact of high-rate wireless LAN surface forming process, concertedness between cutting parameter and cutter is poor, cannot obtain excellent process program.
Summary of the invention:
The object of this invention is to provide a kind of for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality.
Above-mentioned object is realized by following technical scheme:
A kind of for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, its composition comprises: two or four high speed rose cutter, high-speed milling cutter stock-removing efficiency described in announcement and the experimental technique of machined surface quality collision problem, the modification method of described high-speed milling cutter cutting movement track, the finished surface residue unit that high speed rose cutter Mold processing change described in reflection and vibration affect milled surface topography, the cutting of hardened steel process program that the high speed rose cutter stock-removing efficiency described in solution is conflicted with machined surface quality.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in two, diameter 20mm, there is identical structure, respectively with rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, cutting depth 0.2 mm, with rotating speed 2000 rpm, speed of feed 1800 mm/min, line-spacing 0.5mm, cutting depth 0.1mm two kinds of process programs, carry out cutting of hardened steel contrast experiment, disclose conflicting of high-speed milling cutter stock-removing efficiency and machined surface quality.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in four has different modal parameters respectively, high speed rose cutter Mold processing described in four is respectively 92mm, 100mm, 105mm, 110mm, its diameter is 20mm, with rotating speed 5000 rpm, speed of feed 3000 mm/min, line-spacing 0.3mm, cutting depth 0.2 mm, the process program that milling cutter machining inclination angle is 15 °, carry out the Cr12MoV hardened steel milled surface topography experiment of high-speed milling hardness HRC 55 ~ 60, the influencing characteristic of high speed rose cutter vibration to hardened steel milled surface topography described in acquisition.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in utilization and the kinematic relation of workpiece and machine tool system, high speed rose cutter cutting movement equation of locus described in foundation, high speed rose cutter vibration described in employing and blade alignment error cause tool coordinate origin displacement increment, described high speed rose cutter cutting movement equation of locus is revised, establishes milled surface topography formation condition.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, cutter-work the contact relation of the high speed rose cutter described in utilization, with described high speed rose cutter adjacent point of contact place parameter of cutting layer, high speed rose cutter finished surface residue unit described in structure, these finished surface residue unit structural parameters comprise: along the residue unit length l on line-spacing direction
e1and l
e2, along the residue unit length l in direction of feed
f1and l
f2, residue unit maximum height h
max, the residue unit height h on the peak section of line-spacing direction
e1, the residue unit height h on the minimum point section of line-spacing direction
e2, the residue unit height h on direction of feed peak section
f1, and the residue unit height h on direction of feed minimum point section
f2.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, the high speed rose cutter finished surface residue unit structural parameters described in employing, obtain line-spacing direction residue unit maximum height h
emax, direction of feed residue unit maximum height h
fmax, along the residue unit maximum length l on line-spacing direction
emax, along the residue unit maximum length l in direction of feed
fmax.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, adopt claim 5, method according to claim 6, adopt claim 5, method according to claim 6, extract the be evenly distributed degree h of residue unit in finished surface normal direction
max, the intensity of variation l of finished surface residue unit length in feeding and line-spacing direction, and residue unit distribution arrangement and direction of feed angle
w, the change of quantitative description milled surface topography and milling cutter cut the finished surface texture formed.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, adopt claim 4, claim 7, carry out diameter 20mm, the emulation of the high speed rose cutter milled surface topography described in 2 teeth that Mold processing is 92mm, by finished surface residue unit height and cell distribution degree of uniformity, obtain and meet stock-removing efficiency 1200 mm
2/ min requirement, described high speed rose cutter vibration amplitude reaches minimum value 3.7 μm, and the process program that finished surface scallop-height reaches minimum value 0.6 μm is rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, cutting depth 0.2mm, described high speed Inclination Angle of Ball-end Cutter 15 °.
Described for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, utilize with according to claim 8 identical four described high speed rose cutter, under identical cutting depth 0.2mm and described high speed Inclination Angle of Ball-end Cutter 15 ° of conditions, respectively with rotating speed 3000 rpm, speed of feed 2400 mm/min, line-spacing 0.5mm, rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, rotating speed 6000 rpm, speed of feed 3600 mm/min, line-spacing 0.3mm tetra-kinds of process programs, carry out described high speed rose cutter cutting experiment, the highest by stock-removing efficiency, the optimum evaluation index of machined surface quality, obtain and identical high-speed milling hardened steel process program according to claim 8.
Beneficial effect:
1. the present invention is to provide a kind of job operation of high-speed milling hardened steel.The method utilizes high-speed milling hardened steel to test, obtain high-speed milling cutter cutting vibration to milled surface topography influencing characteristic, adopt tool coordinate origin displacement increment, milling cutter cutting movement track is revised, establish milled surface topography formation condition, high speed rose cutter finished surface residue unit is utilized to be out of shape and distribution character, high speed rose cutter milled surface topography feature is described, obtain the process program meeting hardened steel high-efficient cutting and high machined surface quality requirement, be applicable to solve and decline because of milling cutter modal parameter and milling cutter vibrates the collision problem of working (machining) efficiency and the machined surface quality caused.
There is the difference of essence in the present invention and existing High Speed Milling of Hardened Steels process, existing High Speed Milling of Hardened Steels process, take machined surface roughness as design object, and the forming process on control high-rate wireless LAN surface not yet in effect, the milled surface topography obtained has diversity and uncertainty, the demand of highly-efficient processing large-scale precision mould cannot be met, and the present invention is tested by high-speed milling hardened steel, utilize high-speed milling cutter cutting vibration to milled surface topography influencing characteristic, consider high-speed milling cutter stock-removing efficiency, mode, cutting vibration, between the multiple characteristic quantity of Tool in Cutting movement locus, reciprocation is on the impact of high-rate wireless LAN surface forming process, set up the milled surface topography characteristic model under milling cutter vibration condition, by Alternative Process Plans simulation and experiment, propose the process solving stock-removing efficiency in high-speed milling hardened steel and machined surface quality collision problem.
Accompanying drawing illustrates:
Accompanying drawing 1 is hardened steel milled surface topography figure of the present invention.
Accompanying drawing 2 is Mold processing 92mm milling cutter vibration experiment result figure.
Accompanying drawing 3 is Mold processing 100mm milling cutter vibration experiment result figure.
Accompanying drawing 4 is Mold processing 105mm milling cutter vibration experiment result figure.
Accompanying drawing 5 is Mold processing 110mm milling cutter vibration experiment result figure.
Accompanying drawing 6 is milled surface topography figure of Mold processing 92mm milling cutter cutting of hardened steel experiment.
Accompanying drawing 7 is milled surface topography figure of Mold processing 100mm milling cutter cutting of hardened steel experiment.
Accompanying drawing 8 is milled surface topography figure of Mold processing 105mm milling cutter cutting of hardened steel experiment.
Accompanying drawing 9 is milled surface topography figure of Mold processing 110mm milling cutter cutting of hardened steel experiment.
Accompanying drawing 10 is rose cutter Cutter coordinate system figure.
Accompanying drawing 11 is rose cutter direction of feed polar plots.
Accompanying drawing 12 is milling cutter finished surface residue unit figure.
Accompanying drawing 13 is milling cutter finished surface residue unit depth maps.
Accompanying drawing 14 is the finished surface residue unit height maps along milling cutter line-spacing direction tolerance.
Accompanying drawing 15 is the finished surface residue unit height maps along milling cutter direction of feed tolerance.
Accompanying drawing 16 is analysis result figure of milling cutter finished surface residue unit distributed model.
Accompanying drawing 17 is hardened steel milled surface topography experimental results figure.
Accompanying drawing 18 is milled surface topography simulation result figure of scheme 1 in table 4.
Accompanying drawing 19 is milled surface topography simulation result figure of scheme 2 in table 4.
Accompanying drawing 20 is milled surface topography simulation result figure of scheme 3 in table 4.
Accompanying drawing 21 is milled surface topography simulation result figure of scheme 4 in table 4.
Accompanying drawing 22 is milling cutter Results of Vibration figure in the cutting experiment of scheme 1 in table 4.
Accompanying drawing 23 is milling cutter Results of Vibration figure in the cutting experiment of scheme 2 in table 4.
Accompanying drawing 24 is milling cutter Results of Vibration figure in the cutting experiment of scheme 3 in table 4.
Accompanying drawing 25 is milling cutter Results of Vibration figure in the cutting experiment of scheme 4 in table 4.
Accompanying drawing 26 is milled surface topography experimental results figure of scheme 1 in table 4.
Accompanying drawing 27 is milled surface topography experimental results figure of scheme 2 in table 4.
Accompanying drawing 28 is milled surface topography experimental results figure of scheme 3 in table 4.
Accompanying drawing 29 is milled surface topography experimental results figure of scheme 4 in table 4.
Embodiment:
Embodiment 1:
A kind of for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, its composition comprises: two or four high speed rose cutter, high-speed milling cutter stock-removing efficiency described in announcement and the experimental technique of machined surface quality collision problem, the modification method of described high-speed milling cutter cutting movement track, the finished surface residue unit that high speed rose cutter Mold processing change described in reflection and vibration affect milled surface topography, the cutting of hardened steel process program that the high speed rose cutter stock-removing efficiency described in solution is conflicted with machined surface quality.
Embodiment 2:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in two, diameter 20mm, there is identical structure, respectively with rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, cutting depth 0.2 mm, with rotating speed 2000 rpm, speed of feed 1800 mm/min, line-spacing 0.5mm, cutting depth 0.1mm two kinds of process programs, carry out cutting of hardened steel contrast experiment, disclose conflicting of high-speed milling cutter stock-removing efficiency and machined surface quality.
Embodiment 3:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in four has different modal parameters respectively, high speed rose cutter Mold processing described in four is respectively 92mm, 100mm, 105mm, 110mm, its diameter is 20mm, with rotating speed 5000 rpm, speed of feed 3000 mm/min, line-spacing 0.3mm, cutting depth 0.2 mm, the process program that milling cutter machining inclination angle is 15 °, carry out the Cr12MoV hardened steel milled surface topography experiment of high-speed milling hardness HRC 55 ~ 60, the influencing characteristic of high speed rose cutter vibration to hardened steel milled surface topography described in acquisition.
Embodiment 4:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, high speed rose cutter described in utilization and the kinematic relation of workpiece and machine tool system, high speed rose cutter cutting movement equation of locus described in foundation, high speed rose cutter vibration described in employing and blade alignment error cause tool coordinate origin displacement increment, described high speed rose cutter cutting movement equation of locus is revised, establishes milled surface topography formation condition.
Embodiment 5:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, cutter-work the contact relation of the high speed rose cutter described in utilization, with described high speed rose cutter adjacent point of contact place parameter of cutting layer, high speed rose cutter finished surface residue unit described in structure, these finished surface residue unit structural parameters comprise: along the residue unit length l on line-spacing direction
e1and l
e2, along the residue unit length l in direction of feed
f1and l
f2, residue unit maximum height h
max, the residue unit height h on the peak section of line-spacing direction
e1, the residue unit height h on the minimum point section of line-spacing direction
e2, the residue unit height h on direction of feed peak section
f1, and the residue unit height h on direction of feed minimum point section
f2.
Embodiment 6:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, the high speed rose cutter finished surface residue unit structural parameters described in employing, obtain line-spacing direction residue unit maximum height h
emax, direction of feed residue unit maximum height h
fmax, along the residue unit maximum length l on line-spacing direction
emax, along the residue unit maximum length l in direction of feed
fmax.
Embodiment 7:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, adopt claim 5, method according to claim 6, extract the be evenly distributed degree h of residue unit in finished surface normal direction
max, the intensity of variation l of finished surface residue unit length in feeding and line-spacing direction, and residue unit distribution arrangement and direction of feed angle
w, the change of quantitative description milled surface topography and milling cutter cut the finished surface texture formed.
Embodiment 8:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, adopt claim 4, claim 7, carry out diameter 20mm, the emulation of the high speed rose cutter milled surface topography described in 2 teeth that Mold processing is 92mm, by finished surface residue unit height and cell distribution degree of uniformity, obtain and meet stock-removing efficiency 1200 mm
2/ min requirement, described high speed rose cutter vibration amplitude reaches minimum value 3.7 μm, and the process program that finished surface scallop-height reaches minimum value 0.6 μm is rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, cutting depth 0.2mm, described high speed Inclination Angle of Ball-end Cutter 15 °.
Embodiment 9:
Described in embodiment 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, utilize with according to claim 8 identical four described high speed rose cutter, under identical cutting depth 0.2mm and described high speed Inclination Angle of Ball-end Cutter 15 ° of conditions, respectively with rotating speed 3000 rpm, speed of feed 2400 mm/min, line-spacing 0.5mm, rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, rotating speed 6000 rpm, speed of feed 3600 mm/min, line-spacing 0.3mm tetra-kinds of process programs, carry out described high speed rose cutter cutting experiment, the highest by stock-removing efficiency, the optimum evaluation index of machined surface quality, obtain and identical high-speed milling hardened steel process program according to claim 8.
Embodiment 10:
Described in embodiment 1-9 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, the impact of described high speed rose cutter vibration on hardened steel milled surface topography, the method comprises the steps:
1. the high speed rose cutter cutting of hardened steel mould contrast experiment described in.
Adopt in diameter 20mm high speed rose cutter Machining Hardened Steels mould, the process program of hardened steel machined surface quality and working (machining) efficiency and technological effect contrast, as shown in table 1 and Fig. 1:
The process program of table 1 cutting of hardened steel and Contrast on effect
In hardened steel finishing, there is the process program of the high speed of mainshaft and speed of feed, high working (machining) efficiency can be obtained, but vibration cutting is strong, its machined surface roughness reaches Ra3.2 μm ~ 6.3 μm, and superficial makings direction there are differences, this will significantly increase the time of the polishing of hardened steel finished surface and grinding step, and die manufacturing cycle is extended.Adopt the first scheme in table 1, effectively reduce vibration cutting, make machined surface roughness reach Ra0.8 μm, improve hardened steel machined surface quality, but working (machining) efficiency is significantly reduced.Above-mentioned analysis result shows, affects by vibration cutting, hardened steel milling efficiency with there is stronger technique between machined surface quality and conflict.
The described influencing characteristic of high speed rose cutter vibration to hardened steel milled surface topography.
For disclosing high-speed milling cutter cutting vibration to milled surface topography influencing characteristic, adopting and changing milling cutter Mold processing, to change the method for milling cutter mode and cutting vibration characteristic, carry out the hardened steel milled surface topography experiment under vibration cutting impact.Wherein, lathe is UCP710 boring-milling center, and workpiece material is Cr12MoV hardened steel, hardness HRC 55 ~ 60.Indexable rose cutter diameter is 20mm, and the number of teeth is 2.Speed of mainshaft 5000rpm, feed engagement 0.3mm, line-spacing 0.3mm, cutting depth is 0.2mm.For ensureing cutting speed, milling cutter machining inclination angle adopts 15 °.
Described high speed rose cutter modal analysis result shows, changes Mold processing, milling cutter ratio of damping, rigidity and natural frequency generation significant change.According to this result, select Mold processing to be 92mm, 100mm, 105mm, 110mm high-speed milling cutter respectively, carry out cutting of hardened steel experiment, obtain high-speed milling hardened steel vibration cutting and milled surface topography, as shown in table 2 and Fig. 2 to Fig. 9.
Table 2 high-speed milling cutter modal parameter
By table 2 and Fig. 2 to Fig. 9, dither is produced when milling cutter Mold processing is 100mm, milling cutter dither when Mold processing is 110mm becomes milling cutter main frequency of vibration, and workpiece machining surface pattern significant change occurs thereupon, exacerbates conflicting of working (machining) efficiency and machined surface quality further.
Embodiment 11:
Described in embodiment 1-9 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, the modification method of described high speed rose cutter cutting movement track:
1. milling cutter cutting movement equation of locus
During described high speed rose cutter cutting workpiece, under the effect of dynamic cutting force and centrifugal force, the beat that vibration cutting produces directly affects cutting movement track and is formed, and milled surface topography is changed.By the mutual alignment relation of workpiece, cutter and machine tool system, build lathe coordinate system O
j-X
jy
jz
jwith tool coordinate system O
d– X
dy
dz
d, extract milling cutter feeding and line-spacing direction vector, as shown in Figure 10, Figure 11.
Obtaining milling cutter cutting movement equation of locus is thus:
（1）
In formula, x
p j, y
p j, z
p jfor the coordinate of t milling cutter point of contact in lathe coordinate system, x
t d, y
t d, z
t dfor the coordinate of t milling cutter point of contact in tool coordinate system, x
0, y
0, z
0for the coordinate of tool coordinate initial point in lathe coordinate system, f is milling cutter speed of feed vector, λ
x u, λ
y u, λ
z ube respectively milling cutter speed of feed vector and lathe coordinate system X
j, Y
j, Z
jaxle clamp angle, i is milling cutter feeding number of times, λ
x v, λ
y v, λ
z vbe respectively milling cutter line-spacing direction vector and lathe coordinate system X
j, Y
j, Z
jaxle clamp angle.
Tool coordinate origin displacement Incremental SAT method.
Under milling cutter vibration effect, tool coordinate initial point because vibration beat produces displacement increment is:
（2）
In formula: △ x
o, △ y
o, △ z
obe respectively tool coordinate initial point along X
j, Y
j, Z
jthe displacement increment that axle produces, △ d
1for the displacement of milling cutter centre of sphere radial beat, l is milling cutter Mold processing; △ α
1for the starting phase angle of cutter deflection, get positive sign when cutter swings to point of contact direction, cutter deviates from when point of contact direction swings gets negative sign,
jtfor a jth cutter tooth Chosen Point t in XOY plane relative to the corner of starting point on sword line, n is milling cutter rotating speed, and t is the time.
Milling cutter blade capable of rotating positions alignment error causes tool coordinate initial point to produce displacement increment:
（3）
In formula: △ x '
o, △ y '
o, △ z '
obe respectively tool coordinate initial point along X
j, Y
j, Z
jthe displacement increment that axle produces, △ d
3, △ d
4be respectively blade center relative to the radial error at ball head knife center and axial error, △ α
2for the starting phase angle of blade eccentric, off-centered cutting edge participates in getting positive sign when cutting, and the cutting edge at deflection center participates in removing negative sign when cutting,
jtfor a jth cutter tooth Chosen Point t in XOY plane relative to the corner of starting point on sword line.
Milling cutter cutting movement equation of locus does modification method.
Utilize formula (2), formula (3) do following correction to milling cutter point of contact equation of locus:
（4）
Embodiment 12:
Described in embodiment 1-9 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, the model building method of described high speed rose cutter milled surface topography:
1. the high speed rose cutter finished surface residue unit described in,
According to cutter-work contact relation and milling cutter cutting movement equation of locus, establish milled surface topography formation condition, by the calculating of adjacent cutter point of contact place parameter of cutting layer in finished surface forming process, build high speed rose cutter finished surface residue unit, its characteristic parameter is as shown in Figure 12, Figure 13, Figure 14, Figure 15.
Described high speed rose cutter finished surface residue unit characteristic parameter,
Utilize in table 2 the milling cutter result of oscillation and cutting parameter condition of testing and recording, adopt formula (4) and above-mentioned model metrics method, carrying out Mold processing is the analysis of 92mm and 110mm milling cutter finished surface residue unit characteristic parameter, as shown in table 3:
Table 3 finished surface residue unit analysis result
In table: l is milling cutter Mold processing, h
emaxfor line-spacing direction residue unit maximum height, h
fmaxfor direction of feed residue unit maximum height, l
emaxfor along the residue unit maximum length on line-spacing direction, l
fmaxfor along the residue unit maximum length in direction of feed.
This analysis result shows, under identical cutting parameter condition, the change of milling cutter Mold processing and vibration make finished surface residue unit create distortion in various degree, the finished surface residue unit model extracted, and can reflect the change of milling cutter Mold processing and the impact of vibration on milled surface topography.
The distribution character of residue unit on finished surface,
Adopt said method, carry out the continuous solving of residue unit along Tool in Cutting movement locus, obtain the distribution character of residue unit on finished surface:
（5）
In formula: h
maxfor the distributed degrees of residue unit in finished surface normal direction, l is the intensity of variation of finished surface residue unit length in feeding and line-spacing direction, l
maxfor residue unit maximum length, l
minfor residue unit minimum length, it is the vector of unit length of direction of feed; For the vector of unit length of processing residue unit distribution arrangement,
wfor residue unit distribution arrangement and direction of feed angle, 0 °≤
w≤ 90 °.
High speed rose cutter milled surface topography and experimental technique.
Employing formula (5), carries out high speed rose cutter milled surface topography and analyzes and experiment.Wherein, rose cutter diameter 20mm, the number of teeth is 2, and Mold processing is 92mm, rotating speed 5000rpm, feed engagement 0.3mm, line-spacing 0.3mm, and cutting depth is 0.2mm, machining inclination angle 15 °, and workpiece material is Cr12MoV hardened steel, hardness HRC 55 ~ 60.Finished surface residue unit distribution character is analyzed and experimental result, as shown in Figure 16, Figure 17.
Model analysis and experimental result show, by milling cutter vibration effect, the Cutting trajectory of milling cutter two cutters tooth there are differences, and residue unit is all changed in length and height, there is obvious directivity in its distribution on finished surface, causes milled surface topography to have significant textural characteristics.
Embodiment 13:
Described in embodiment 1-9 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, described high speed rose cutter wash cut hardened steel milled surface topography emulation and methods of experiments.
Milling cutter vibration data acquisition methods.
Rose cutter diameter 20mm, the number of teeth is 2, and Mold processing is 92mm, and workpiece material is Cr12MoV hardened steel, hardness HRC 55 ~ 60.1200mm is remained on for making milling cutter stock-removing efficiency
2/ min and 1080 mm
2/ min level, adopt identical four high speed rose cutter, under identical cutting depth 0.2mm and milling cutter machining inclination angle 15 ° of conditions, respectively with rotating speed 3000 rpm, speed of feed 2400 mm/min, line-spacing 0.5mm, rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, rotating speed 6000 rpm, speed of feed 3600 mm/min, line-spacing 0.3mm tetra-kinds of process programs, carry out high speed rose cutter cutting experiment, obtain milling cutter vibration data.
Described high speed rose cutter is washed and is cut the emulation of hardened steel milled surface topography and hardened steel Cutting Process scheme acquisition methods.
According to milling cutter vibration experiment result, utilize milling cutter cutting movement track correct model, build high speed rose cutter cutting of hardened steel finished surface residue unit model, adopt finished surface residue unit model analysis method, carry out the emulation of high speed rose cutter cutting of hardened steel milled surface topography, by finished surface residue unit height and cell distribution degree of uniformity, obtain and meet stock-removing efficiency 1200 mm
2/ min requirement, milling cutter vibration amplitude reaches minimum value 3.7 μm, and the process program that finished surface scallop-height reaches minimum value 0.6 μm is rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, cutting depth 0.2mm, milling cutter machining inclination angle 15 °.
The experiment of high-speed milling hardened steel milled surface topography and process program verification method.
Adopt with identical with step 1 four high speed rose cutter, under identical cutting depth 0.2mm and milling cutter machining inclination angle 15 ° of conditions, respectively with rotating speed 3000 rpm, speed of feed 2400 mm/min, line-spacing 0.5mm, rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, rotating speed 6000 rpm, speed of feed 3600 mm/min, line-spacing 0.3mm tetra-kinds of process programs, carry out high speed rose cutter cutting experiment, the highest by stock-removing efficiency, the optimum evaluation index of machined surface quality, obtain the high-speed milling hardened steel process program identical with step 2.
Milled surface topography simulation and experiment Comparative result method.
Adopt the emulation of high speed rose cutter milled surface topography and the experimental result of step 2, step 3, as shown in table 4 and Figure 18 to Figure 29:
Table 4 milled surface topography simulation and experiment scheme
By finished surface residue unit height and cell distribution degree of uniformity, above-mentioned process program is evaluated, process program the most close is required with stock-removing efficiency and machined surface quality, be followed successively by scheme 3, scheme 2, scheme 1, scheme 4, to obtain process program preferred sequence identical with pressing milled surface topography experimental results.The milled surface topography model analysis method proposed, can solve the working (machining) efficiency in high-speed milling cutter cutting of hardened steel and machined surface quality collision problem.
Claims (9)
1. one kind for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, its composition comprises: two or four high speed rose cutter, it is characterized in that: the high-speed milling cutter stock-removing efficiency described in announcement and the experimental technique of machined surface quality collision problem, the modification method of described high-speed milling cutter cutting movement track, the finished surface residue unit that high speed rose cutter Mold processing change described in reflection and vibration affect milled surface topography, the cutting of hardened steel process program that the high speed rose cutter stock-removing efficiency described in solution is conflicted with machined surface quality.
2. according to claim 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, it is characterized in that: the high speed rose cutter described in two, diameter 20mm, there is identical structure, respectively with rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, cutting depth 0.2 mm, with rotating speed 2000 rpm, speed of feed 1800 mm/min, line-spacing 0.5mm, cutting depth 0.1mm two kinds of process programs, carry out cutting of hardened steel contrast experiment, disclose conflicting of high-speed milling cutter stock-removing efficiency and machined surface quality.
3. according to claim 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, it is characterized in that: four have different modal parameters respectively described high speed rose cutter, high speed rose cutter Mold processing described in four is respectively 92mm, 100mm, 105mm, 110mm, its diameter is 20mm, with rotating speed 5000 rpm, speed of feed 3000 mm/min, line-spacing 0.3mm, cutting depth 0.2 mm, the process program that milling cutter machining inclination angle is 15 °, carry out the Cr12MoV hardened steel milled surface topography experiment of high-speed milling hardness HRC 55 ~ 60, the influencing characteristic of high speed rose cutter vibration to hardened steel milled surface topography described in acquisition.
4. according to claim 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, it is characterized in that: the high speed rose cutter described in utilization and the kinematic relation of workpiece and machine tool system, high speed rose cutter cutting movement equation of locus described in foundation, high speed rose cutter vibration described in employing and blade alignment error cause tool coordinate origin displacement increment, described high speed rose cutter cutting movement equation of locus is revised, establishes milled surface topography formation condition.
5. according to claim 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, it is characterized in that: the cutter-work contact relation of the high speed rose cutter described in utilization, with described high speed rose cutter adjacent point of contact place parameter of cutting layer, high speed rose cutter finished surface residue unit described in structure, these finished surface residue unit structural parameters comprise: along the residue unit length l on line-spacing direction
e1and l
e2, along the residue unit length l in direction of feed
f1and l
f2, residue unit maximum height h
max, the residue unit height h on the peak section of line-spacing direction
e1, the residue unit height h on the minimum point section of line-spacing direction
e2, the residue unit height h on direction of feed peak section
f1, and the residue unit height h on direction of feed minimum point section
f2.
6. according to claim 1 for solving the hardened steel job operation that stock-removing efficiency is conflicted with machined surface quality, it is characterized in that: the high speed rose cutter finished surface residue unit structural parameters described in employing, obtain line-spacing direction residue unit maximum height h
emax, direction of feed residue unit maximum height h
fmax, along the residue unit maximum length l on line-spacing direction
emax, along the residue unit maximum length l in direction of feed
fmax.
7. according to claim 1 for solving the hardened steel that stock-removing efficiency is conflicted with machined surface quality
Job operation, is characterized in that: adopt claim 5, method according to claim 6, extract the be evenly distributed degree h of residue unit in finished surface normal direction
max, the intensity of variation l of finished surface residue unit length in feeding and line-spacing direction, and residue unit distribution arrangement and direction of feed angle
w, the change of quantitative description milled surface topography and milling cutter cut the finished surface texture formed.
8. according to claim 1 for solving the hardened steel that stock-removing efficiency is conflicted with machined surface quality
Job operation, it is characterized in that: adopt claim 4, claim 7, carry out diameter 20mm, the emulation of the high speed rose cutter milled surface topography described in 2 teeth that Mold processing is 92mm, by finished surface residue unit height and cell distribution degree of uniformity, obtain and meet stock-removing efficiency 1200 mm
2/ min requirement, described high speed rose cutter vibration amplitude reaches minimum value 3.7 μm, and the process program that finished surface scallop-height reaches minimum value 0.6 μm is rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, cutting depth 0.2mm, described high speed Inclination Angle of Ball-end Cutter 15 °.
9. according to claim 1 for solving the hardened steel that stock-removing efficiency is conflicted with machined surface quality
Job operation, it is characterized in that: utilize with according to claim 8 identical four described high speed rose cutter, under identical cutting depth 0.2mm and described high speed Inclination Angle of Ball-end Cutter 15 ° of conditions, respectively with rotating speed 3000 rpm, speed of feed 2400 mm/min, line-spacing 0.5mm, rotating speed 4000 rpm, speed of feed 3000 mm/min, line-spacing 0.4mm, rotating speed 5000 rpm, speed of feed 4000 mm/min, line-spacing 0.3mm, rotating speed 6000 rpm, speed of feed 3600 mm/min, line-spacing 0.3mm tetra-kinds of process programs, carry out described high speed rose cutter cutting experiment, the highest by stock-removing efficiency, the optimum evaluation index of machined surface quality, obtain and identical high-speed milling hardened steel process program according to claim 8.
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