CN109571142B - Instantaneous temperature determination method and system for rake face of integral flat-head end mill - Google Patents
Instantaneous temperature determination method and system for rake face of integral flat-head end mill Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 36
- 241000755266 Kathetostoma giganteum Species 0.000 title claims abstract description 19
- 238000003801 milling Methods 0.000 claims abstract description 166
- 238000005520 cutting process Methods 0.000 claims abstract description 43
- 238000010008 shearing Methods 0.000 claims description 12
- 238000009826 distribution Methods 0.000 claims description 11
- PCTMTFRHKVHKIS-BMFZQQSSSA-N (1s,3r,4e,6e,8e,10e,12e,14e,16e,18s,19r,20r,21s,25r,27r,30r,31r,33s,35r,37s,38r)-3-[(2r,3s,4s,5s,6r)-4-amino-3,5-dihydroxy-6-methyloxan-2-yl]oxy-19,25,27,30,31,33,35,37-octahydroxy-18,20,21-trimethyl-23-oxo-22,39-dioxabicyclo[33.3.1]nonatriaconta-4,6,8,10 Chemical compound C1C=C2C[C@@H](OS(O)(=O)=O)CC[C@]2(C)[C@@H]2[C@@H]1[C@@H]1CC[C@H]([C@H](C)CCCC(C)C)[C@@]1(C)CC2.O[C@H]1[C@@H](N)[C@H](O)[C@@H](C)O[C@H]1O[C@H]1/C=C/C=C/C=C/C=C/C=C/C=C/C=C/[C@H](C)[C@@H](O)[C@@H](C)[C@H](C)OC(=O)C[C@H](O)C[C@H](O)CC[C@@H](O)[C@H](O)C[C@H](O)C[C@](O)(C[C@H](O)[C@H]2C(O)=O)O[C@H]2C1 PCTMTFRHKVHKIS-BMFZQQSSSA-N 0.000 claims description 9
- 230000008569 process Effects 0.000 claims description 9
- 238000005482 strain hardening Methods 0.000 claims description 9
- 238000004364 calculation method Methods 0.000 claims description 7
- 238000003754 machining Methods 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000001125 extrusion Methods 0.000 claims 1
- 230000020169 heat generation Effects 0.000 claims 1
- 238000012544 monitoring process Methods 0.000 abstract description 2
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- 229910001069 Ti alloy Inorganic materials 0.000 description 4
- 230000008859 change Effects 0.000 description 4
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- 238000004088 simulation Methods 0.000 description 4
- 230000001052 transient effect Effects 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000004422 calculation algorithm Methods 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
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- 238000005260 corrosion Methods 0.000 description 1
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- 125000004122 cyclic group Chemical group 0.000 description 1
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- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
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Abstract
The invention discloses a method and a system for determining the instantaneous temperature of the front cutter face of an integral flat-head end mill. Establishing a model of an instantaneous contact angle between the milling cutter and a workpiece; establishing an undeformed chip thickness model under the condition that the milling cutter and the workpiece are undeformed and vibrate and a cutting edge cuts into the workpiece from a distance from a machined surface every time the milling cutter mills; calculating the thickness of the undeformed chip according to the undeformed chip thickness model; establishing a temperature field model of the temperature rise influence of a heat source in a first deformation area on the front cutter face of the milling cutter; establishing a temperature field model of the temperature rise influence of a heat source in a second deformation area on the front cutter face of the milling cutter; and calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model. The temperature field models of the heat source of the first deformation area and the heat source of the second deformation area are respectively established, so that the accuracy of monitoring the temperature of the milling cutter in the cutting process is improved.
Description
Technical Field
The invention relates to the field of integral flat-head end mills, in particular to a method and a system for determining the instantaneous temperature of the front cutter face of an integral flat-head end mill.
Background
The titanium alloy has good specific strength, specific rigidity, heat resistance and corrosion resistance, and is widely applied to the fields of aviation, aerospace, energy, building, military and the like. The titanium alloy has low thermal conductivity, so when the titanium alloy is milled, a large amount of cutting heat is generated between the milling cutter and a titanium alloy workpiece, and the temperature of the milling cutter is rapidly increased instantly, so that the abrasion of the milling cutter is aggravated. The temperature of the milling cutter is particularly important to research because the change of the cutting temperature directly affects the quality of the surface of a workpiece and the machining precision.
In the prior art, a prediction model for analyzing and calculating the average temperature of a cutter-chip contact surface is provided for the peripheral milling of a plane, and the effectiveness of the model is verified by measuring the average transient temperature of the front cutter surface of the hard alloy milling cutter through a thermocouple. And establishing a numerical model for determining the temperature distribution of the cutter in the process of milling the straight teeth by adopting a finite difference method. The finite element method is used for simulating the temperature of the contact surface of the workpiece and the cutter and the temperature distribution inside the workpiece in the process of milling the aluminum alloy thin-wall part at a high speed. A moving heat source method is adopted, and real milling heating and cooling time is considered, so that a finite element temperature simulation model which accords with the characteristics of high-speed milling is established. The temperature and the heat distribution of the cutter-chip contact surface in the milling process of the difficult-to-cut material are measured by using a single thermocouple, and the heat distribution ratio of the cutter-chip contact surface is optimized by using a response surface method. The thermal model is used for describing the temperature cyclic change of the workpiece in the end milling process by considering the friction factor of the rear cutter face, and the influence of different processing conditions, the abrasion width of the rear cutter face and the position of the cutter on the temperature change of the workpiece is shown theoretically and experimentally. And the accurate simulation of the temperature change of the workpiece is realized, and the calculation time of the algorithm is obviously shorter than that of a finite element method. A novel end face milling thermal model is established by adopting a semi-analytic method under the condition that the influence of a milling cutter bottom edge on cutting temperature is considered for the first time, and model simulation results and experimental results show that a temperature field has very important influence on the diffusion abrasion of WC cutters with different cobalt bonding concentrations. A series of finite element numerical simulation and experiments are adopted, and the size effect is considered, the research on the influence of cutting heat on the process of processing the aluminum alloy by the micro-end milling is carried out, and the average cutting temperature on the cutting edge is reduced along with the increase of the radius of the tool nose. The shear heat source of the first deformation zone and the friction heat source of the cutting scraps of the second deformation zone are considered, a tool temperature field of a numerical analysis method established based on a finite difference technology is provided, and the influence of the cobalt content in the tool on the wear of the rear tool face of the tungsten carbide tool is found to be obvious when the tungsten carbide tool is subjected to milling processing.
According to the current situation of cutter temperature modeling research in machining at present, research work mainly focuses on temperature modeling of an indexable milling cutter with the characteristic of interrupted machining, related research on modeling of a transient temperature field of a rake face of a helical-edge end mill is not involved, and the temperature field of the rake face of the milling cutter cannot be accurately determined.
Disclosure of Invention
The invention aims to provide a method and a system for determining the instantaneous temperature of the rake face of an integral flat-head end mill, which can accurately determine the temperature field of the rake face of the mill.
In order to achieve the purpose, the invention provides the following scheme:
a method of determining an instantaneous temperature of a rake surface of a one-piece flat-head end mill, the method of determining comprising:
converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
wherein, γnAt a normal rake angle ofcIs the contact length of the cutting scraps;
establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
in the process that the milling cutter machines the workpiece, the milling cutter does not deform and vibrate, and an undeformed chip thickness h model is established under the condition that a cutting edge cuts into the workpiece from a position away from a machined surface every time of milling;
calculating the thickness h of the undeformed chip according to the model of the thickness h of the undeformed chip;
establishing a temperature field model of which the temperature rise influence is generated on the front cutter face of the milling cutter by a first deformation area heat source to obtain a first temperature field model, wherein the first deformation area heat source is heat generated in the shearing sliding of the cutting chip in a shearing plane;
establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a second deformation area heat source to obtain a second temperature field model, wherein the second deformation area heat source is heat generated by the contact of the chips and the milling cutter rake face;
establishing a temperature field model under a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
and calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
Optionally, the establishing a model of the instantaneous contact angle θ between the milling cutter and the workpiece specifically includes:
discretizing the milling cutter along an axial cutting direction into m thickness dz ═ ApA wafer of/m, ApFor milling depth, when the thickness of each wafer is small enough, the thread is a straight line BD, the straight line BD is used as a hypotenuse, a right-angle triangle ABD is established, the right-angle side in the horizontal direction is AB, and the right-angle side in the vertical direction is AD;
calculating an instantaneous contact angle theta between the milling cutter and the workpiece according to formulas (2), (3) and (4);
wherein A ispBeta is the helix angle of the milling cutter, and R is the radius of the milling cutter.
Optionally, the establishing the undeformed chip thickness h model specifically includes:
each milling of the cutting edge cuts into the workpiece from a distance from the machined surface
wherein,
wherein v isfFor feed rate, AeFor milling width, fzThe feed per tooth, z is the milling cutter edge number, n is the machine tool rotation speed, thetaenAt an angle of cut, θexR is the radius of the cutter for the cut-out angle, and ∠ XOD is the cut-in angle of the cutter at which the undeformed chip thickness is maximized.
Optionally, the establishing a temperature field model in which the first deformation zone heat source generates a temperature rise influence on the milling cutter rake face, and the obtaining the first temperature field model specifically includes:
establishing a pair of a primary heat source point dl of a first deformation zone and a mirror image heat source point dl' of the primary heat source point of the first deformation zone along an arbitrary point P in the X directionI(0,0, z) respectively calculating the temperature rise value delta T of the primary heat source point of the first deformation regionI(x,0, z) and a temperature rise value DeltaT of the mirror image heat source pointI'(x,0,z)；
Calculating an arbitrary point P along the first deformation region in the X directionITemperature rise value DeltaT of (0,0, z)rake-I(0,0,z)；
ΔTrake-I(x,0,z)＝ΔTI(x,0,z)+ΔTI'(x,0,z) (9)
Wherein λ istH (theta) is the undeformed chip thickness, phi, for the thermal conductivity of the milling cutternNormal shear angle, ηcFor chip discharge angle, αwThe thermal diffusivity of the workpiece is represented by l, and the distance from a primary heat source point dl of the first deformation zone to an origin (0,0, 0); k0For modifying the zero order of Bessel functions of the second kind, RlHeat source point dl to point P of the primary heat source of the first deformation zoneI(x,0,0) Distance of (1), R'lHeat source point dl to point P for the mirror image heat source of the first deformation zoneIA distance of (x,0, 0);
established first deformation zone heat intensity qIModel (model)
Vsh＝Vcosλs(12)
Wherein, tauABCD-maxUltimate shear stress, σ, for the shear plane ABCDABCDIs the yield stress of the shear plane ABCD, A is the reference strain rate and the initial yield stress at the reference temperature, B is the strain hardening modulus of the workpiece, εABCD-PIs the effective plastic strain of the shear plane ABCD, n is the strain hardening index of the workpiece, C is the strain rate hardening parameter of the workpiece,for effective plastic strain rate of shear plane ABCD,
for reference strain rate, T is the current temperature, TrFor reference temperature, TmIs the melting temperature of the workpiece, m is the heat softening index of the workpiece, VshThe moving speed of the heat source in the first deformation region, V is the cutting speed, lambdasIs the edge rake angle.
Optionally, the establishing of the temperature field model in which the second deformation zone heat source generates a temperature rise influence on the milling cutter rake face includes:
establishing a primary heat source point pair of the second deformation region and a mirror image heat source point pair of the second deformation region at any point P along the X' directionII(x',0,0) and respectively calculating the temperature rise delta T of the primary heat source point of the second deformation regionII(x',0,0) and the second deformation zoneMirror image heat source point delta TII'(x',0,0)；
Calculating an arbitrary point P within the second deformation region heat source along the X' directionIITemperature rise Δ T of (x',0,0)rake-II(x',0,0)；
ΔTrake-II(x',0,0)＝ΔTII(x',0,0)+ΔTII'(x',0,0) (16)
Where lc (θ) is the chip length corresponding to different instantaneous contacts, nrIs the strain hardening index, R, of the rake face of the milling cutteri-2Point to point P for the heat source of the second deformation regionIIDistance of (x',0,0), Ri-2'Point to point P of heat source on mirror image heat source of the second deformation zoneIIDistance of (x',0,0), w is bevel turning width, λsW' is the component of the bevel turning width in the direction of the cutting edge;
establishing the first deformation zone thermal strength qIA model;
Achip(θ)＝lc(θ)wc(20)
wherein σs-wIs the yield stress, η, of the material of the workpiececAngle of chip outflow frake-chip(theta, x') is the frictional force between the chip contact surfaces, sigman-r(theta, x ') is the positive stress on the rake face at the instant contact angle between the milling cutter and the workpiece, theta, coordinate x', sigmatipIs the normal stress at the tip of the milling cutter, V is the cutting speed, VcAs regards the speed of movement of the chips,
is the average friction angle of the contact surface between the milling cutter and the chip, Achip(theta) is the contact area between the milling cutter and the chip, wcZeta is a coefficient for determining the pressure distribution of the chip contact surface, phi, for the chip widthnIs a normal shear angle;
calculating the heat distribution ratio of the heat source in the second deformation region to the front tool face
Wherein alpha iswIs the thermal diffusivity, lambda, of the workpiecetIs the thermal conductivity, lambda, of the milling cutterwIs the thermal conductivity coefficient of the workpiece material, CBTo calculate BII-rakeCoefficients in the formula (θ).
Optionally, the establishing a temperature field model under a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face to obtain the milling cutter rake face temperature field model specifically includes:
calculating the temperature T of any point P (X ',0,0) along the X ' direction under the coordinate system X ' Y ' Z ' corresponding to the rake face of the milling cutterrake(x',0,0)
Trake(x',0,0)＝ΔTrake-I(lc+Z,0,0)+ΔTrake-II(x',0,0)+T0(23)
Wherein, T0Is the initial temperature of the rake face of the cutting rake.
An instantaneous temperature determination system for a rake surface of a one-piece flat-head end mill, the determination system comprising:
the coordinate system establishing module is used for converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
the instantaneous contact angle model establishing module is used for establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
an undeformed chip thickness model building module, which builds an undeformed chip thickness h model under the condition that the milling cutter does not deform and vibrate and the cutting edge cuts from a position away from the machined surface every time in the process of machining the workpiece by the milling cutter;
the undeformed chip thickness calculation module is used for calculating the undeformed chip thickness h according to the undeformed chip thickness h model;
the first temperature field model establishing module is used for establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a first deformation zone heat source to obtain a first temperature field model, wherein the first deformation zone heat source is heat generated in the shearing slippage of the cutting chip in the shearing plane;
the second temperature field model establishing module is used for establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a second deformation zone heat source to obtain a second temperature field model, wherein the second deformation zone heat source is heat generated by the contact of the chips and the milling cutter rake face;
the milling cutter rake face temperature field model building module is used for building a temperature field model under a coordinate system corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
and the instantaneous temperature calculation module is used for calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects: the invention discloses a method and a system for determining the instantaneous temperature of the front cutter face of an integral flat-head end mill, which respectively establish temperature field models of a heat source in a first deformation area and a heat source in a second deformation area, improve the accuracy of temperature monitoring of the milling cutter in the cutting process, prolong the service life of the milling cutter, and simultaneously improve the surface quality and the machining precision of a machined workpiece.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a flow chart of a method of determining the instantaneous temperature of the rake face of an integral flat-head end mill provided by the present invention;
FIG. 2 is a schematic diagram of the heat distribution of the heat source of the first deformation zone and the heat source of the second deformation zone provided by the present invention;
fig. 3 is a schematic view of a micro-element blade of the milling cutter provided by the invention;
FIG. 4 is a schematic illustration of the undeformed chip thickness provided by the present invention;
FIG. 5 is a schematic view of a heat source in a first deformation region according to the present invention;
FIG. 6 is a schematic view of a heat source in a second deformation region according to the present invention;
fig. 7 is a schematic diagram of a transient temperature field of a rake face of the milling cutter provided by the present invention;
fig. 8 is a schematic diagram of the transient temperature field of the rake face of the milling cutter according to the present invention as a function of milling time;
FIG. 9 is a block diagram of the instantaneous temperature determination system for the rake face of the integrated flat-head end mill provided by the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a method and a system for determining the instantaneous temperature of the rake face of an integral flat-head end mill, which can accurately determine the temperature field of the rake face of the mill.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1, a method of determining an instantaneous temperature of a rake surface of a one-piece flat-head end mill, the method comprising:
step 100: converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
wherein, γnAt a normal rake angle ofcIs the contact length of the cutting scraps;
step 200: establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
step 300: in the process that the milling cutter machines the workpiece, the milling cutter does not deform and vibrate, and an undeformed chip thickness h model is established under the condition that a cutting edge cuts into the workpiece from a position away from a machined surface every time of milling;
step 400: calculating the thickness h of the undeformed chip according to the model of the thickness h of the undeformed chip;
step 500: establishing a temperature field model of which the temperature rise influence is generated on the front cutter face of the milling cutter by a first deformation area heat source to obtain a first temperature field model, wherein the first deformation area heat source is heat generated in the shearing sliding of the cutting chip in a shearing plane;
step 600: establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a second deformation area heat source to obtain a second temperature field model, wherein the second deformation area heat source is heat generated by the contact of the chips and the milling cutter rake face;
step 700: establishing a temperature field model under a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
step 800: and calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
The model for establishing the instantaneous contact angle theta between the milling cutter and the workpiece specifically comprises the following steps:
as shown in fig. 3, the milling cutter is discretized in the axial cutting direction into m thickness dz ═ apA wafer of/m, ApFor milling depth, when the thickness of each wafer is small enough, the thread is a straight line BD, the straight line BD is used as a hypotenuse, a right-angle triangle ABD is established, the right-angle side in the horizontal direction is AB, and the right-angle side in the vertical direction is AD;
calculating an instantaneous contact angle theta between the milling cutter and the workpiece according to formulas (2), (3) and (4);
wherein A ispBeta is the helix angle of the milling cutter, and R is the radius of the milling cutter.
As shown in fig. 4, the establishing of the undeformed chip thickness h model specifically includes:
each milling of the cutting edge cuts into the workpiece from a distance from the machined surface
wherein,
wherein v isfFor feed rate, AeFor milling width, fzThe feed per tooth, z is the milling cutter edge number, n is the machine tool rotation speed, thetaenAt an angle of cut, θexR is the radius of the cutter for the cut-out angle, and ∠ XOD is the cut-in angle of the cutter at which the undeformed chip thickness is maximized.
As shown in fig. 2, 5, and 6, the establishing a temperature field model in which the first deformation region heat source generates a temperature rise influence on the milling cutter rake face, and the obtaining the first temperature field model specifically includes:
establishing a pair of a primary heat source point dl of a first deformation zone and a mirror image heat source point dl' of the primary heat source point of the first deformation zone along an arbitrary point P in the X directionI(0,0, z) respectively calculating the temperature rise value delta T of the primary heat source point of the first deformation regionI(x,0, z) and a temperature rise value DeltaT of the mirror image heat source pointI'(x,0,z)；
Calculating an arbitrary point P along the first deformation region in the X directionITemperature rise value DeltaT of (0,0, z)rake-I(0,0,z)；
ΔTrake-I(x,0,z)＝ΔTI(x,0,z)+ΔTI'(x,0,z) (9)
Wherein λ istH (theta) is the undeformed chip thickness, phi, for the thermal conductivity of the milling cutternNormal shear angle, ηcFor chip discharge angle, αwThe thermal diffusivity of the workpiece is represented by l, and the distance from a primary heat source point dl of the first deformation zone to an origin (0,0, 0); k0For modifying the zero order of Bessel functions of the second kind, RlHeat source point dl to point P of the primary heat source of the first deformation zoneIDistance of (x,0,0), R'lHeat source point dl to point P for the mirror image heat source of the first deformation zoneIA distance of (x,0, 0);
established first deformation zone heat intensity qIModel (model)
Vsh＝Vcosλs(12)
Wherein, tauABCD-maxUltimate shear stress, σ, for the shear plane ABCDABCDIs the yield stress of the shear plane ABCD, A is the reference strain rate and the initial yield stress at the reference temperature, B is the strain hardening modulus of the workpiece, εABCD-PIs the effective plastic strain of the shear plane ABCD, n is the strain hardening index of the workpiece, C is the strain rate hardening parameter of the workpiece,
for effective plastic strain rate of shear plane ABCD,
for reference strain rate, T is the current temperature, TrFor reference temperature, TmIs the melting temperature of the workpiece, m is the heat softening index of the workpiece, VshThe moving speed of the heat source in the first deformation region, V is the cutting speed, lambdasIs the edge rake angle.
The establishing of the temperature field model in which the heat source in the second deformation region generates temperature rise influence on the milling cutter rake face specifically comprises:
establishing a primary heat source point pair of the second deformation region and a mirror image heat source point pair of the second deformation region at any point P along the X' directionII(x',0,0) and respectively calculating the temperature rise delta T of the primary heat source point of the second deformation regionII(x',0,0) and the second deformation region mirror heat source point Δ TII'(x',0,0)；
Calculating an arbitrary point P within the second deformation region heat source along the X' directionIITemperature rise Δ T of (x',0,0)rake-II(x',0,0)；
ΔTrake-II(x',0,0)＝ΔTII(x',0,0)+ΔTII'(x',0,0) (16)
Where lc (θ) is the chip length corresponding to different instantaneous contacts, nrIs the strain hardening index, R, of the rake face of the milling cutteri-2Point to point P for the heat source of the second deformation regionIIDistance of (x',0,0), Ri-2'Point to point P of heat source on mirror image heat source of the second deformation zoneIIDistance of (x',0,0), w is bevel turning width, λsW' is the component of the bevel turning width in the direction of the cutting edge;
establishing the first deformation zone thermal strength qIA model;
Achip(θ)＝lc(θ)wc(20)
wherein σs-wIs the yield stress, η, of the material of the workpiececAngle of chip outflow frake-chip(theta, x') is the frictional force between the chip contact surfaces, sigman-r(theta, x ') is the positive stress on the rake face at the instant contact angle between the milling cutter and the workpiece, theta, coordinate x', sigmatipIs the normal stress at the tip of the milling cutter, V is the cutting speed, VcAs regards the speed of movement of the chips,
is the average friction angle of the contact surface between the milling cutter and the chip, Achip(theta) is the contact area between the milling cutter and the chip, wcZeta is a coefficient for determining the pressure distribution of the chip contact surface, phi, for the chip widthnIs a normal shear angle;
as shown in fig. 7 and 8, the heat distribution ratio of the heat source to the rake face in the second deformation region was calculated
Wherein alpha iswIs the thermal diffusivity, lambda, of the workpiecetIs the thermal conductivity, lambda, of the milling cutterwIs the thermal conductivity coefficient of the workpiece material, CBTo calculate BII-rakeCoefficients in the formula (θ).
The establishing of the temperature field model under the coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face to obtain the milling cutter rake face temperature field model specifically comprises the following steps:
calculating the temperature T of any point P (X ',0,0) along the X ' direction under the coordinate system X ' Y ' Z ' corresponding to the rake face of the milling cutterrake(x',0,0)
Trake(x',0,0)＝ΔTrake-I(lc+Z,0,0)+ΔTrake-II(x',0,0)+T0(23)
Wherein, T0Is the initial temperature of the rake face of the cutting rake.
As shown in fig. 9, an instantaneous temperature determination system for the rake face of a one-piece flat-head end mill, the determination system comprising:
the coordinate system establishing module 1 is used for converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
the instantaneous contact angle model establishing module 2 is used for establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
an undeformed chip thickness model building module 3, which builds an undeformed chip thickness h model under the condition that the milling cutter does not deform and vibrate and the cutting edge cuts from a position away from the machined surface every time in the process of machining the workpiece by the milling cutter;
the undeformed chip thickness calculation module 4 is used for calculating the undeformed chip thickness h according to the undeformed chip thickness h model;
the first temperature field model establishing module 5 is used for establishing a temperature field model in which a first deformation zone heat source generates temperature rise influence on the milling cutter rake face to obtain a first temperature field model, wherein the first deformation zone heat source is heat generated in the shearing slippage of the cutting chip in a shearing plane;
the second temperature field model establishing module 6 is used for establishing a temperature field model in which a second deformation zone heat source generates a temperature rise influence on the milling cutter rake face to obtain a second temperature field model, wherein the second deformation zone heat source is heat generated by the chips contacting with the milling cutter rake face;
the milling cutter rake face temperature field model establishing module 7 is used for establishing a temperature field model under a coordinate system corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
and the instantaneous temperature calculation module 8 is used for calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (7)
1. A method of determining an instantaneous temperature of a rake face of a one-piece flat-head end mill, the method comprising:
converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
wherein, γnAt a normal rake angle ofcIs the contact length of the cutting scraps;
establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
in the process that the milling cutter machines the workpiece, the milling cutter does not deform and vibrate, and an undeformed chip thickness h model is established under the condition that a cutting edge cuts into the workpiece from a position away from a machined surface every time of milling;
calculating the thickness h of the undeformed chip according to the model of the thickness h of the undeformed chip;
establishing a temperature field model of which the temperature rise influence is generated on the front cutter face of the milling cutter by a first deformation area heat source to obtain a first temperature field model, wherein the first deformation area heat source is heat generated in the shearing sliding of the cutting chip in a shearing plane;
establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a second deformation area heat source to obtain a second temperature field model, wherein the second deformation area heat source is heat generated by the contact of the chips and the milling cutter rake face;
establishing a temperature field model under a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
and calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
2. The method according to claim 1, wherein the modeling of the instantaneous contact angle θ between the milling cutter and the workpiece comprises:
discretizing the milling cutter along an axial cutting direction into m thickness dz ═ ApA wafer of/m, ApFor milling depth, when the thickness of each wafer is small enough, the thread is a straight line BD, the straight line BD is used as a hypotenuse, a right-angle triangle ABD is established, the right-angle side in the horizontal direction is AB, and the right-angle side in the vertical direction is AD;
calculating an instantaneous contact angle theta between the milling cutter and the workpiece according to formulas (2), (3) and (4);
wherein A ispBeta is the helix angle of the milling cutter, and R is the radius of the milling cutter.
3. The method of claim 2, wherein the establishing the undeformed chip thickness h model specifically comprises:
each milling of the cutting edge cuts into the workpiece from a distance from the machined surface
Wherein,
wherein,
wherein v isfFor feed rate, AeFor milling width, fzThe feed per tooth, z is the milling cutter edge number, n is the machine tool rotation speed, thetaenAt an angle of cut, θexR is the radius of the cutter for the cut-out angle, and ∠ XOD is the cut-in angle of the cutter at which the undeformed chip thickness is maximized.
4. The method for determining the instantaneous temperature of the rake surface of the one-piece flat-head end mill according to claim 1, wherein the establishing a temperature field model of the temperature rise influence of the heat source in the first deformation region on the rake surface of the milling cutter specifically comprises:
establishing a first deformation zoneA pair of a heat generation source point dl and a mirror image heat source point dl' of the primary heat source point of the first deformation region at an arbitrary point P in the X directionI(0,0, z) respectively calculating the temperature rise value delta T of the primary heat source point of the first deformation regionI(x,0, z) and a temperature rise value DeltaT of the mirror image heat source pointI'(x,0,z)；
Calculating an arbitrary point P along the first deformation region in the X directionITemperature rise value DeltaT of (0,0, z)rake-I(0,0,z)；
ΔTrake-I(x,0,z)＝ΔTI(x,0,z)+ΔTI'(x,0,z) (9)
Wherein λ istH (theta) is the undeformed chip thickness, phi, for the thermal conductivity of the milling cutternNormal shear angle, ηcFor chip discharge angle, αwThe thermal diffusivity of the workpiece is represented by l, and the distance from a primary heat source point dl of the first deformation zone to an origin (0,0, 0); k0For modifying the zero order of Bessel functions of the second kind, RlHeat source point dl to point P of the primary heat source of the first deformation zoneIDistance of (x,0,0), Rl' Heat source point dl to point P of heat source mirrored to the first deformation regionIA distance of (x,0, 0);
established first deformation zone heat intensity qIModel (model)
Vsh＝V cosλs(12)
Wherein, tauABCD-maxUltimate shear stress, σ, for the shear plane ABCDABCDIs the yield stress of the shear plane ABCD, A is the reference strain rate and the initial yield stress at the reference temperature, B is the strain hardening modulus of the workpiece, εABCD-PIs the effective plastic strain of the shear plane ABCD, n is the strain hardening index of the workpiece, C is the strain rate hardening parameter of the workpiece,
for effective plastic strain rate of shear plane ABCD,
for reference strain rate, T is the current temperature, TrFor reference temperature, TmIs the melting temperature of the workpiece, m is the heat softening index of the workpiece, VshThe moving speed of the heat source in the first deformation region, V is the cutting speed, lambdasIs the edge rake angle.
5. The method for determining the instantaneous temperature of the rake face of the one-piece flat-head end mill according to claim 1, wherein the establishing a temperature field model of the temperature rise influence of the heat source in the second deformation region on the rake face of the milling cutter specifically comprises:
establishing a primary heat source point pair of the second deformation region and a mirror image heat source point pair of the second deformation region at any point P along the X' directionII(x',0,0) and respectively calculating the temperature rise delta T of the primary heat source point of the second deformation regionII(x',0,0) and the second deformation region mirror heat source point Δ TII'(x',0,0)；
Calculating an arbitrary point P within the second deformation region heat source along the X' directionIITemperature rise Δ T of (x',0,0)rake-II(x',0,0)；
ΔTrake-II(x',0,0)＝ΔTII(x',0,0)+ΔTII'(x',0,0) (16)
Where lc (θ) is the chip length corresponding to different instantaneous contacts, nrIs the strain hardening index, R, of the rake face of the milling cutteri-2Point to point P for the heat source of the second deformation regionIIDistance of (x',0,0), Ri-2'Point to point P of heat source on mirror image heat source of the second deformation zoneIIDistance of (x',0,0), w is bevel turning width, λsW' is the component of the bevel turning width in the direction of the cutting edge;
establishing the second deformation zone thermal strength qII(θ, x') model;
Achip(θ)＝lc(θ)wc(20)
wherein σs-wIs the yield stress, η, of the material of the workpiececAngle of chip outflow frake-chip(theta, x') is the frictional force between the chip contact surfaces, sigman-r(theta, x ') is the positive stress on the rake face at the instant contact angle between the milling cutter and the workpiece, theta, coordinate x', sigmatipIs the normal stress at the tip of the milling cutter, V is the cutting speed, VcAs regards the speed of movement of the chips,
is the average friction angle of the contact surface between the milling cutter and the chip, Achip(theta) is the contact area between the milling cutter and the chip, wcZeta is a coefficient for determining the pressure distribution of the chip contact surface, phi, for the chip widthnIs a normal shear angle;
calculating the heat distribution ratio B of the heat source heat in the second deformation region to the front tool faceII-rake(θ)
Wherein alpha iswIs the thermal diffusivity, lambda, of the workpiecetIs the thermal conductivity, lambda, of the milling cutterwIs the thermal conductivity coefficient of the workpiece material, CBTo calculate BII-rakeCoefficients in the formula (θ).
6. The method for determining the instantaneous temperature of the rake face of the integral flat-head end mill according to claim 1, wherein the establishing of the temperature field model under the coordinate system X ' Y ' Z ' corresponding to the rake face of the milling cutter specifically comprises:
calculating the temperature T of any point P (X ',0,0) along the X ' direction under the coordinate system X ' Y ' Z ' corresponding to the rake face of the milling cutterrake(x',0,0)
Trake(x',0,0)＝ΔTrake-I(lc+Z,0,0)+ΔTrake-II(x',0,0)+T0(23)
Wherein, T0Is the initial temperature of the rake face of the cutting rake.
7. An instantaneous temperature determination system for a rake face of a one-piece flat-head end mill, the determination system comprising:
the coordinate system establishing module is used for converting the coordinate system XYZ into a coordinate system X ' Y ' Z ' corresponding to the milling cutter rake face;
the instantaneous contact angle model establishing module is used for establishing a model of an instantaneous contact angle theta between the milling cutter and a workpiece;
an undeformed chip thickness model building module, which builds an undeformed chip thickness h model under the condition that the milling cutter does not deform and vibrate and the cutting edge cuts from a position away from the machined surface every time in the process of machining the workpiece by the milling cutter;
the undeformed chip thickness calculation module is used for calculating the undeformed chip thickness h according to the undeformed chip thickness h model;
the first temperature field model establishing module is used for establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a first deformation zone heat source to obtain a first temperature field model, wherein the first deformation zone heat source is heat generated in the shearing slippage of the cutting chip in the shearing plane;
the second temperature field model establishing module is used for establishing a temperature field model of which the temperature rise influence is generated on the milling cutter rake face by a second deformation zone heat source to obtain a second temperature field model, wherein the second deformation zone heat source is heat generated by extrusion and friction of the chips and the milling cutter rake face;
the milling cutter rake face temperature field model building module is used for building a temperature field model under a coordinate system corresponding to the milling cutter rake face to obtain a milling cutter rake face temperature field model;
and the instantaneous temperature calculation module is used for calculating the instantaneous temperature of the milling cutter rake face according to the first temperature field model, the second temperature field model and the milling cutter rake face temperature field model.
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