CN114939693B - Rapid design and performance optimization method for complex profile milling cutter - Google Patents
Rapid design and performance optimization method for complex profile milling cutter Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The scheme belongs to the technical field of hard alloy milling cutter design and manufacture, and particularly relates to a rapid design and performance optimization method for a complex molded line milling cutter, which comprises the following steps: the method comprises the following steps of adopting a discretization method to discretize a cutting edge of a complex profile milling cutter into infinite cutting edge microelements at equal intervals along the axial direction, and step two: on the premise of ensuring the safety of the cutting edge, determining the optimal rake angle, relief angle, cutting edge radius, matched cutting speed and single tooth feeding amount; step three: fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions; step four: and according to the manufacturability principle, each micro-element cutter model combination stack is restrained, so that the optimal design of the complex line milling cutter is realized. According to the scheme, a cutting state equilibrium design method is adopted, the profile milling cutter is axially scattered into a micro-element cutter unit, so that the most severe cutting edge position in the cutting state can obtain the optimal bearing capacity, and the safety of the cutting edge is ensured.
Description
Technical Field
The scheme belongs to the technical field of hard alloy milling cutter design and manufacture, and particularly relates to a rapid design and performance optimization method for a complex molded line milling cutter.
Background
At present, the traditional cutter design flow is as follows: tool material preference, tool geometry design, tool manufacture, coating preference, cutting test and tool optimization, ultimately forming the actual tool product. The various performance parameters of the cutter are verified through a large number of cutting tests at the later stage, which is a complex and long process. Once the test results are not ideal, the associated pre-process needs to be redesigned, in addition to the design and time costs, and so forth until finalized. The later the problem is found, the higher the cost incurred by the redesign. The tool design method has low efficiency, long period and high production and test cost, and sometimes larger repetition of the design scheme can occur, so that huge waste is caused, the requirement of quickly, accurately and reliably developing a high-performance tool is not met, and an advanced tool design method is urgently needed for guiding, so that the development speed of the tool is accelerated.
The patent number 202210166479.0 discloses a non-standard complex groove type milling cutter and a processing method of a chip breaker thereof, wherein the cutting edge profile of the milling cutter is fir-tree-shaped, the milling cutter is provided with 3 or 4 teeth, the front angle of the milling cutter is 0 DEG, the helix angle is 100-15 DEG, each tooth back of the milling cutter is provided with a chip breaker which is consistent with the track of the cutting edge profile, the chip breaker profile is corrugated, and the chip breakers of each tooth are staggered by the wavelength/number of teeth according to the next staggered wavelength of the spiral direction of the milling cutter; the chip breaker profile satisfies the following relationship: r is greater than R; and r= (L/2×l/2+h ×h is 2×r×h)/(2×h), wherein: l is the wave distance, h is the wave depth, and r is the radius of the upper half-wave arc; r is the radius of the arc of the lower half wave. The chip breaker machining method is to draw the milling cutter chip breaker line with AutoCAD drawing tool software, guide it into the num software of the control system of the numerical control machine tool, automatically generate the chip breaker machining program, and automatically machine the milling cutter chip breaker by the machine tool. However, no teaching is given as to how to design a high performance milling cutter.
Therefore, how to predict and evaluate the performance of newly developed tools is the most interesting problem of tool engineers, and obtaining tool geometric parameters and tool material performance indexes quickly based on reliability principles is a key problem to be solved by tool design preferentially.
Disclosure of Invention
The purpose of the scheme is to provide a rapid design and performance optimization method for the complex line milling cutter so as to design the complex line milling cutter with high performance.
In order to achieve the above purpose, the present solution provides a method for rapidly designing and optimizing performance of a complex profile milling cutter, comprising the following steps:
step one: the complex line milling cutter cutting edge is axially and equidistantly scattered into infinite cutting edge microelements by adopting a discretization method, each cutting edge microelement is simplified into a linear edge, and the complex line milling cutter can be regarded as the combined superposition of infinite simple microelement bevel cutting models;
step two: on the premise of ensuring the safety of the cutting edge, the infinitesimal cutting force, the cutting temperature and the cutting edge stress are analyzed and calculated according to a cutter durability formula, and the optimal front angle, the optimal rear angle, the optimal cutting edge radius, the optimal cutting speed and the optimal single-tooth feeding amount are determined; the tool durability formula is:
wherein C is T Is a coefficient and is cut except the cutting amountThe conditions are related to various factors.V, f and a, respectively p An index of influence on tool durability T, and +.>
v is cutting speed, f is feed amount, a p Is the cutting depth.
Step three: fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions;
step four: according to the manufacturability principle, each micro-element cutter model combination stack is restrained, the comprehensive balance of design, manufacturing cost and performance is considered, and the optimal design of the complex molded line milling cutter is realized
The principle of the scheme is that: the method is characterized in that a 'cutting state equilibrium design method' is adopted, a molded line milling cutter is axially discretized into a micro-element cutter unit, cutting parameters, metal removal amount and cutting stroke of each point are matched by taking the safety limit stress of a cutter material as a boundary condition, and geometrical parameters of each point are custom-made optimized design, so that the position of the cutting edge with the worst cutting state can obtain the optimal bearing capacity, and the safety of the cutting edge is ensured.
Further, the front angle range is-8 degrees to 30 degrees, the rear angle range is 5 degrees to 15 degrees, the cutter edge radius range is 10 to 50 mu m, the cutting speed range is 5 to 150m/min, and the single tooth feeding amount range is 0.01 to 0.3mm/rev.
Further, the cutting speed was 150m/mi.
Further, the single tooth feed amount was 0.3mm/rev.
Detailed Description
The following is a further detailed description of the embodiments:
example 1
A rapid design and performance optimization method for a complex profile milling cutter comprises the following steps:
(1) The complex line milling cutter cutting edge is axially and equidistantly scattered into infinite cutting edge microelements by adopting a discretization method, each cutting edge microelement is simplified into a linear edge, and the complex line milling cutter can be regarded as the combined superposition of infinite simple microelement bevel cutting models.
(2) On the premise of ensuring the safety of the cutting edge, the optimal design is carried out aiming at a micro-element cutter model with the most severe cutting state or working condition, the optimal geometric parameter of the optimized micro-element cutter delta I is 15 degrees of front angle, 10 degrees of rear angle, 28 mu m of cutting edge radius, the matching cutting speed is 80m/min, and the single-tooth feeding amount is 0.17mm/rev.
(3) And (3) fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions.
(4) And according to the manufacturability principle, each micro-element cutter model combination stack is restrained, and the comprehensive balance of design, manufacturing cost and performance is considered, so that the optimal design of the complex line milling cutter is realized.
Example 2
A rapid design and performance optimization method for a complex profile milling cutter comprises the following steps:
(1) The complex line milling cutter cutting edge is axially and equidistantly scattered into infinite cutting edge microelements by adopting a discretization method, each cutting edge microelement is simplified into a linear edge, and the complex line milling cutter can be regarded as the combined superposition of infinite simple microelement bevel cutting models.
(2) On the premise of ensuring the safety of the cutting edge, the optimal design is carried out according to a micro-element cutter model with the most severe cutting state or working condition, the optimal geometric parameter of the optimized micro-element cutter delta I is a rake angle of-8 degrees, a relief angle of 5 degrees, the radius of the cutting edge of 10 mu m, the matching cutting speed of 5m/min and the single tooth feeding amount of 0.01mm/rev.
(3) And (3) fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions.
(4) And according to the manufacturability principle, each micro-element cutter model combination stack is restrained, and the comprehensive balance of design, manufacturing cost and performance is considered, so that the optimal design of the complex line milling cutter is realized.
Example 3
A rapid design and performance optimization method for a complex profile milling cutter comprises the following steps:
(1) The complex line milling cutter cutting edge is axially and equidistantly scattered into infinite cutting edge microelements by adopting a discretization method, each cutting edge microelement is simplified into a linear edge, and the complex line milling cutter can be regarded as the combined superposition of infinite simple microelement bevel cutting models.
(2) On the premise of ensuring the safety of the cutting edge, the optimal design is carried out according to a micro-element cutter model with the most severe cutting state or working condition, the optimal geometric parameter of the optimized micro-element cutter delta I is 30 degrees in front angle, 15 degrees in back angle and 50 mu m in cutting edge radius, the matching cutting speed is 150m/min, and the single-tooth feeding amount is 0.3mm/rev.
(3) And (3) fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions.
(4) And according to the manufacturability principle, each micro-element cutter model combination stack is restrained, and the comprehensive balance of design, manufacturing cost and performance is considered, so that the optimal design of the complex line milling cutter is realized.
The effects of tool rake angle, tool relief angle, actual edge radius, cutting speed, actual single tooth feed on cutting temperature, and cutting edge stress are shown in tables 1 to 5, respectively.
TABLE 1 influence of tool rake angle on cutting temperature and cutting edge stress
TABLE 2 influence of tool rake angle on cutting temperature and cutting edge stress
TABLE 3 influence of actual edge radius on cutting temperature and cutting edge stress
TABLE 4 influence of cutting speed on cutting temperature and cutting edge stress
TABLE 5 influence of actual single tooth feed on cutting temperature and edge stress
As can be seen from table 1, the cutting temperature also showed a tendency to increase with increasing tool rake angle, but a certain fluctuation occurred locally, the tool stress showed a tendency to decrease first and then increase with increasing tool rake angle, and the tool stress appeared to be the minimum when the tool rake angle was 10 °. As can be seen from Table 2, the optimum edge radius is 28 μm because the edge stress is minimal at this time. As can be seen from Table 3, the optimal cutting speed was 80m/min, at which the edge stress was the lowest. As can be seen from Table 4, the optimal actual single tooth feed amount is 0.17mm/rev. Compared with other schemes, the cutting edge of the embodiment 1 has the least stress and the best edge tipping resistance.
The application provides a brand new design idea, which adopts a cutting state equilibrium design method to axially disperse a molded line milling cutter into a micro-element cutter unit, takes the safety limit stress of a cutter material as a boundary condition, matches the cutting parameters, the metal removal amount and the cutting stroke of each point, and custom optimizes and designs the geometric parameters of each point, so that the position of the cutting edge with the worst cutting state can obtain the optimal bearing capacity, and the safety of the cutting edge is ensured. The application provides a scientific method for rapid design and performance optimization of the complex line milling cutter.
Finally, it is noted that the above-mentioned embodiments illustrate rather than limit the application, and that those skilled in the art will be understood that various changes in form and details may be made therein without departing from the spirit and scope of the application as defined by the appended claims.
The foregoing is merely exemplary embodiments of the present application, and specific structures and features that are well known in the art are not described in detail herein. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present application, and these should also be considered as the scope of the present application, which does not affect the effect of the implementation of the present application and the utility of the patent. The protection scope of the present application is subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.
Claims (3)
1. A method for rapidly designing and optimizing performance of a complex profile milling cutter is characterized by comprising the following steps:
step one: the complex line milling cutter cutting edge is axially and equidistantly scattered into infinite cutting edge microelements by adopting a discretization method, each cutting edge microelement is simplified into a linear edge, and the complex line milling cutter can be regarded as the combined superposition of infinite simple microelement bevel cutting models;
step two: on the premise of ensuring the safety of the cutting edge, the infinitesimal cutting force, the cutting temperature and the cutting edge stress are analyzed and calculated according to a cutter durability formula, and the optimal front angle, the optimal rear angle, the optimal cutting edge radius, the optimal cutting speed and the optimal single-tooth feeding amount are determined; the tool durability formula is:
wherein C is T As coefficients, those related to cutting conditions other than the cutting amount;v, f and a, respectively p An index of influence on tool durability T, and +.>
Step three: fixing cutting speed and single tooth feeding amount, and sequentially optimizing and designing other micro-element cutter models according to the cutting state of each point of the cutting edge or the severity of working conditions;
step four: according to the manufacturability principle, each micro-element cutter model combination stack is restrained, so that the optimal design of the complex line milling cutter is realized;
the front angle range is-8 degrees to 30 degrees, the rear angle range is 5 degrees to 15 degrees, the cutter edge radius range is 10 to 50 mu m, the cutting speed range is 5 to 150m/min, and the single tooth feeding amount range is 0.01 to 0.3mm/rev.
2. The rapid design and performance optimization method for complex profile milling cutter according to claim 1, wherein the rapid design and performance optimization method is characterized in that: the cutting speed was 150m/min.
3. The rapid design and performance optimization method for complex profile milling cutter according to claim 1, wherein the rapid design and performance optimization method is characterized in that: the single tooth feed is 0.3mm/rev.
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