CN116663193A - Discrete edge end mill design method based on free cutting principle - Google Patents
Discrete edge end mill design method based on free cutting principle Download PDFInfo
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- 238000005520 cutting process Methods 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 23
- 238000013461 design Methods 0.000 title claims abstract description 22
- 230000002093 peripheral effect Effects 0.000 claims abstract description 65
- 238000003801 milling Methods 0.000 claims abstract description 17
- 239000006185 dispersion Substances 0.000 claims abstract description 11
- 238000012545 processing Methods 0.000 claims abstract description 5
- 238000003754 machining Methods 0.000 claims description 9
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- 230000004323 axial length Effects 0.000 claims description 6
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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
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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Abstract
The invention discloses a discrete edge end mill design method based on a free cutting principle, which combines three-dimensional modeling software to design a discrete edge end mill suitable for processing deep cavity complex parts. The free cutting principle is introduced when the discrete edge end mill is designed, and the peripheral edge front cutter surface is designed into a waveform curved surface structure with unequal helix angles; considering the influence of the chip breaker parameters on the cutter performance, introducing a dispersion concept, calculating the ratio between the total width of the chip breaker on a single peripheral edge and the axial total length of the unencumbered chip breaker, and quantifying the relation between the total width of the chip breaker and the axial total length of the peripheral edge. The discrete edge end mill designed by the patent can improve chip removal and heat dissipation effects, reduce axial milling force and inhibit chatter in the milling process.
Description
Technical Field
The invention relates to the field of cutter cutting, in particular to a discrete edge end mill design method based on a free cutting principle.
Background
The end mill is a common machining tool in cutting machining, and in the machining of some deep cavity complex parts, the phenomenon of chip removal interference is easy to occur when the conventional end mill is adopted for machining due to high material removal rate and large axial cutting depth, so that more cutting power is consumed. Meanwhile, overlong chips are easy to generate in the machining process, the chips are curled and wound on the cutter to easily scratch the surface of a machined workpiece, friction between the cutter and the workpiece is increased, temperature rise is caused, the machining precision of the part is deteriorated, and the service life of the cutter is also reduced.
The invention provides a design method of a discrete edge end mill based on a free cutting principle, which introduces the free cutting principle when designing the end mill, designs the front tool face of a peripheral edge into a waveform curved surface structure with unequal helix angles according to the principle, reduces chip removal interference, simultaneously enables the peripheral edge to form a local variable helix angle structure, and can inhibit chatter in the cutting process. And the peripheral edge rear cutter surface is provided with a chip dividing groove, the ratio between the total width of the chip dividing groove on a single peripheral edge and the axial total length of the undivided chip dividing groove is calculated and is called as dispersion, the relation between the total width of the chip dividing groove and the axial total length of the peripheral edge is quantized, and the influence rule of the number of the chip dividing grooves on the chip length can be quantitatively studied. The chip dividing grooves on the peripheral edge can reduce the axial cutting depth of the end mill with discrete edges, reduce the axial milling force, and simultaneously lead the chips to be broken more easily and avoid the generation of curled long chips.
Disclosure of Invention
The invention aims to solve the problems of overlong chips and chip removal interference in actual machining, and provides a discrete edge end mill design method based on a free cutting principle, which comprises the following steps:
designing basic parameters of an end mill;
step two, introducing a free cutting principle, and designing the front tool face of the peripheral edge of the end mill into a waveform curved surface structure with unequal helix angles;
step three, calculating a non-degree-of-freedom coefficient phi of the end mill according to a non-degree-of-freedom calculation formula, judging whether the value is between 1 and 1.15, if so, carrying out the next step, and if not, redesigning the shape of the rake face;
step four, reasonably selecting the feed quantity f of each tooth according to the processing material, designing a chip dividing groove parameter, calculating the dispersion according to the ratio between the total width of the chip dividing groove on a single peripheral edge and the axial total length of the unencumbered chip dividing groove, judging whether the value is between 0.08 and 0.5, if so, carrying out the next step, and if not, redesigning the chip dividing groove parameter;
and fifthly, obtaining a discrete edge end mill three-dimensional model designed by the discrete edge end mill design method based on the free cutting principle.
Further, the basic parameters of the first step include:
(1) Overall dimension L, diameter D, core thickness H, edge length L 1 ；，
(2) Three parameters that have a large impact on milling performance: peripheral edge rake angle gamma z The value range is as follows: 5-15 degrees and Zhou Rendi degrees z1 The value range is as follows: the range of the helical angle beta is 12-16 degrees: 30-35 degrees;
(3) The parameters that have less impact on milling performance are determined empirically for conventional end mills: width of rake face B 1 Taking 2mm, zhou Rendi-flank width B az1 Taking a back angle alpha of 1.5mm and Zhou Rendi z2 Take 15 degree Zhou Rendi degree two flank face width B az2 Taking 1.5mm, the radius R of the flute profile curve of the blade part 1 Taking 2.53mm, R 2 Taking 7.12mm; first relief angle alpha of end edge d1 Taking 10 degrees of the width B of the first rear tool face of the end edge ad1 Taking 2mm, and the second relief angle alpha of the end edge d2 Take 15 °.
Further, the wave-shaped curved surface structure with unequal helix angles designed in the second step is smaller than the width of a Zhou Rendi first rear cutter surface, and the wavelength is smaller than or equal to the length of a quarter of a peripheral edge along the spiral line direction of the peripheral edge.
Further, the non-degree-of-freedom coefficient Φ formula of the third step is:
a in the formula (1) is a single peripheral edge non-free cutting solid of an end millPower consumed by the power line dA 1 、dA 2 、dA 3 、……、dA n For the power of the free cutting of each unit tool on the peripheral edge of the end mill, i=1, 2, 3, … …, n, a total of n unit tools participate in the cutting, where d represents the infinitesimal of the unit tool divided by the peripheral edge,the sum of the power of the free cutting is carried out for each unit tool.
Further, the fourth step reasonably selects the feeding amount f of each tooth according to the processing material, and the designed chip breaker parameters comprise: the whole rotation direction (left rotation, right rotation and staggered arrangement), the shape of the chip separating groove (curve shape, rectangle and triangle), the width of the chip separating groove (equal groove width, variable groove width 1 and variable groove width 2) and the depth (the depth V of the chip separating groove is more than f); when the chip-dividing grooves are designed on the peripheral edges, the axial heights of the chip-dividing grooves on two adjacent peripheral edges are different, so that all the cutting areas of each peripheral edge can be overlapped when the cutter rotates for one circle. Calculating the dispersion according to the ratio between the total width of the chip dividing groove on the single peripheral edge and the axial total length of the non-divided chip dividing groove, judging whether the value is between 0.08 and 0.5, if so, carrying out the next step, and if not, redesigning the chip dividing groove parameters;
further, the formula of the dispersion S in the fourth step is as follows:
in formula (2) 1 、l 2 、l 3 、……、l m Representing the width of each flute on a single peripheral edge, x=1, 2, 3, … …, m, a total of m flutes,representing the total width of all flutes on a single peripheral edge; wherein L is z1 、L z2 、L z3 、……、L ze Representing the axial length of each segment of peripheral edge without chipbreaking on a single peripheral edgeDegree, y=1, 2, 3, … …, e, a total length of e segments, +.>Indicating the total axial length of the single peripheral edge without chipbreakers.
The beneficial effects of the invention are that
According to the method, a free cutting principle is introduced when the end mill is designed, and the peripheral edge front cutter surface is designed into a waveform curved surface structure with unequal helix angles, so that chip removal interference during machining is reduced, chatter during milling is restrained, the waveform curved surface structure with unequal helix angles increases the chip containing space of the end mill, and the material removal rate is improved;
the relation between the total width of the chip dividing grooves and the axial total length of the peripheral edge is quantified through the dispersion relation, and the influence rule of the number of the chip dividing grooves on the chip length can be quantitatively studied;
the chip dividing grooves designed on the peripheral edge and the wavy curved surface structures with unequal spiral angles can improve the heat radiation capability of the discrete edge end mill, so that the chips are easier to break, and the curled long chips are avoided.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a left-hand schematic view of the overall spin direction of the chip breaker;
FIG. 3 is a right-hand schematic view of the overall rotation direction of the chip breaker;
FIG. 4 is a schematic illustration of a staggered arrangement in the overall rotational direction of the chip breaker;
FIG. 5 is a schematic diagram of spline-shaped chip-breaker shapes;
FIG. 6 is a schematic diagram of a rectangular chip breaker shape;
FIG. 7 is a schematic diagram of a triangular chip breaker shape;
FIG. 8 is a schematic diagram of an equal slot width chip breaker;
FIG. 9 is a schematic diagram of a variable slot width 1-type chip breaker;
FIG. 10 is a schematic diagram of a variable slot width 2-type chip breaker;
FIG. 11 is an overall block diagram of a discrete edge end mill designed using the free-cutting principle based discrete edge end mill design method of the present invention;
FIG. 12 is a cross-sectional view of a peripheral edge portion of a discrete edge end mill designed using a discrete edge end mill design method based on the free-cutting principle provided by the present invention;
FIG. 13 is a partial view of a discrete edge end mill end edge designed using a discrete edge end mill design method based on the free cutting principle provided by the present invention;
FIG. 14 is a diagram of the peripheral edge chip breaker and wave form curved surface structure of a discrete edge end mill designed using the design method of the discrete edge end mill based on the free cutting principle provided by the invention;
FIG. 15 is an overall block diagram of a conventional end mill;
FIG. 16 is a graph of simulation results of three-dimensional finite element milling for a conventional end mill;
FIG. 17 is a graph of simulated three-dimensional finite element milling results for a discrete edge end mill corresponding to experiment No. 7;
FIG. 18 is a graph of the sequential extraction of a conventional end mill and experimental milling force F from simulation results z Comparison of simulated values obtained.
Detailed Description
As shown in fig. 1, which is a flow chart of the operation of the present invention, a discrete edge end mill design method based on the free-cutting principle comprises the steps of:
step one, determining basic parameters of an end mill, including:
the overall dimension L is 105mm, the diameter D is 20mm, the core thickness H is 12mm, and the blade length L 1 A helical angle of 30 degrees is 40mm, a four-edge end mill is selected, and four peripheral edges and four end edges are provided; three parameters that have a large impact on milling performance: peripheral edge rake angle gamma z At 10 deg., the first relief angle alpha of the peripheral edge z1 15 deg., and 30 deg. helix angle beta.
The parameters that have less impact on milling performance are determined empirically for conventional end mills: width of rake face B 1 2mm, zhou Rendi a relief surface width B az1 Is 1.5mm, zhou Rendi two relief angle alpha z2 15 DEG, the width B of the second flank of the peripheral edge az2 1.5mm, radius R of the flute profile of the blade 1 The diameter of the particles is 2.53mm,R 2 7.12mm; first relief angle alpha of end edge d1 10 DEG, width B of the first flank of the end edge ad1 2mm, end edge second relief angle alpha d2 15 deg..
Step two, introducing a free cutting principle, designing a peripheral edge rake face into a waveform curved surface structure with unequal helix angles, and enabling the whole waveform to be K long 2 Vertical distance K from peak to trough =10 mm 3 ＝1.5mm。
Step three, adopting a genetic algorithm to calculate the power consumed by each unit cutter in MATLAB software, and then carrying the power into the following formula to calculate a non-degree-of-freedom coefficient phi:
in the formula (1), A is the actual power consumed by the single peripheral edge of the end mill in non-free cutting, dA 1 、dA 2 、dA 3 、……、dA n For the power of the free cutting of each unit tool on the peripheral edge of the end mill, i=1, 2, 3, … …, n, a total of n unit tools participate in the cutting, where d represents the infinitesimal of the unit tool divided by the peripheral edge,the sum of the power of the free cutting is carried out for each unit tool.
Step four, reasonably selecting the feeding quantity f of each tooth according to the processing material, wherein the whole rotation direction of the chip dividing groove is right-handed; the shape of the chip dividing groove is spline curve; the chip dividing grooves are designed to be of variable groove width, the number of the chip dividing grooves on two adjacent peripheral edges is three and four, the width of each chip dividing groove on the peripheral edge of each chip dividing groove adopts variable groove width 1, the front width is 1mm, the depth is 1mm, and the rear width is 1.4mm and the depth is 1.2mm. The width of each chip dividing groove on the peripheral edges of the four chip dividing grooves adopts variable groove width 2, the front width is 1.2mm, the depth is 1mm, the rear width is 1.5mm, and the depth is 1.3mm. The spacing between the chip-dividing grooves is 10mm, and the distance between the chip-dividing grooves on the peripheral edge and the end edge is K 1 ＝5mm、K 2 ＝10mm。
The formula for calculating the peripheral edge dispersion S is as follows:
in formula (2) 1 、l 2 、l 3 、……、l m Representing the width of each flute on a single peripheral edge, x=1, 2, 3, … …, m, a total of m flutes,representing the total width of all flutes on a single peripheral edge; wherein L is z1 、L z2 、L z3 、……、L ze The axial length of the peripheral edge of each segment, which represents the length of the individual peripheral edge in which no chip groove is formed, y=1, 2, 3, … …, e, and a total of e segments, i.e.)>Indicating the total axial length of the single peripheral edge without chipbreakers. The peripheral edge dispersion of the four flutes was calculated to be 0.136 and the peripheral edge dispersion of the three flutes was calculated to be 0.081.
Step five, respectively establishing three-dimensional models of a discrete edge end mill designed by a discrete edge end mill design method based on a free cutting principle and a conventional end mill by adopting SOLIDOORKS software, respectively carrying out finite element simulation experiments by using ABAQUS software, and extracting axial milling force F of the two z And comparing the values of the values.
Step six, listing an orthogonal experiment table for parameters of the chip dividing groove in the design step of the discrete edge end mill design method based on the free cutting principle, wherein the designed orthogonal experiment table is as follows:
orthogonal design table
Taking the chip dividing groove parameter of experiment No. 7 as an example to design a discrete edge end mill, respectively carrying out finite element simulation experiments on the discrete edge end mill and a conventional end mill, respectively establishing a discrete edge end mill three-dimensional model and a conventional end mill three-dimensional model corresponding to experiment No. 7 by SOLIWORKS software, respectively carrying out finite element simulation experiments by ABAQUS software, and extracting axial milling force F of the discrete edge end mill and the conventional end mill z Is compared with the axial milling force F of the conventional end mill and the discrete edge end mill corresponding to experiment number 7 z The results show that the discrete edge end mill corresponding to experiment No. 7 can reduce the axial milling force.
The above examples are only illustrative of the preferred embodiments of the present invention and are not intended to limit the scope of the present invention, and various modifications and improvements made by those skilled in the art to the technical solution of the present invention should fall within the scope of protection defined by the claims of the present invention without departing from the spirit of the design of the present invention.
Claims (6)
1. A method of designing a discrete edge end mill based on the free cutting principle, the method comprising the steps of:
designing basic parameters of an end mill;
step two, introducing a free cutting principle, and designing the front tool face of the peripheral edge of the end mill into a waveform curved surface structure with unequal helix angles;
step three, calculating a non-degree-of-freedom coefficient phi of the end mill according to a non-degree-of-freedom calculation formula, judging whether the value is between 1 and 1.15, if so, carrying out the next step, and if not, redesigning the shape of the rake face;
step four, reasonably selecting the feed quantity f of each tooth according to the processing material, designing a chip dividing groove parameter, calculating the dispersion according to the ratio between the total width of the chip dividing groove on a single peripheral edge and the axial total length of the unencumbered chip dividing groove, judging whether the value is between 0.08 and 0.5, if so, carrying out the next step, and if not, redesigning the chip dividing groove parameter;
and fifthly, obtaining a discrete edge end mill three-dimensional model designed by the discrete edge end mill design method based on the free cutting principle.
2. The method of designing a free-cutting based discrete edge end mill according to claim 1, wherein the end mill basic parameters designed in the step one include:
(1) Overall dimension L, diameter D, core thickness H, edge length L 1 ；
(2) Three parameters that have a large impact on milling performance: peripheral edge rake angle gamma z The value range is as follows: 5-15 degrees and Zhou Rendi degrees z1 The value range is as follows: the range of the helical angle beta is 12-16 degrees: 30-35 degrees;
(3) The parameters that have less impact on milling performance are determined empirically for conventional end mills: width B of peripheral edge rake face 1 Taking 2mm, zhou Rendi-flank width B az1 Taking a back angle alpha of 1.5mm and Zhou Rendi z2 Take 15 degree Zhou Rendi degree two flank face width B az2 Taking 1.5mm, the radius R of the flute profile curve of the blade part 1 Taking 2.53mm, R 2 Taking 7.12mm; first relief angle alpha of end edge d1 Taking 10 degrees of the width B of the first rear tool face of the end edge ad1 Taking 2mm, and the second relief angle alpha of the end edge d2 Take 15 °.
3. The method for designing the discrete edge end mill based on the free cutting principle according to claim 1, wherein the free cutting principle is introduced in the second step, the front tool face of the peripheral edge of the end mill is designed into a waveform curved surface structure with unequal helix angles, the vertical distance from the trough to the crest is smaller than the width of a rear tool face of Zhou Rendi, and the wavelength is smaller than or equal to the length of a quarter of a peripheral edge.
4. The method of designing a free-cutting principle based discrete edge end mill according to claim 1, wherein the third specific content includes: calculating a non-degree-of-freedom coefficient phi of the end mill, and judging whether the value is smaller than 1.15; the non-degree-of-freedom coefficient formula is:
in the formula (1), A is the actual power consumed by the single peripheral edge of the end mill in non-free cutting, dA 1 、dA 2 、dA 3 、……、dA n For the power of the free cutting of each unit tool on the peripheral edge of the end mill, i=1, 2, 3, … …, n, a total of n unit tools participate in the cutting, where d represents the infinitesimal of the unit tool divided by the peripheral edge,the sum of the power of the free cutting is carried out for each unit tool.
5. The method for designing a discrete edge end mill based on the free-cutting principle according to claim 1, wherein the fourth step reasonably selects the feed amount f per tooth according to the machining material, designs the chip breaker depth and ensures that the value is larger than the feed amount per tooth, and the designed chip breaker parameters include: the whole spiral direction (left-handed, right-handed and staggered arrangement), the shape of the chip separating groove (curve type, rectangle and triangle), the width of the chip separating groove (equal groove width, variable groove width 1 and variable groove width 2) and the depth (the depth V of the chip separating groove is more than f).
6. The method for designing a discrete edge end mill based on the free-cutting principle according to claim 1, wherein the dispersion S calculated in the fourth step is expressed as:
in formula (2) 1 、l 2 、l 3 、……、l m Representing the width of each flute on a single peripheral edge, x=1, 2, 3, … …, m, a total of m flutes,representing the total width of all flutes on a single peripheral edge; wherein L is z1 、L z2 、L z3 、……、L ze The axial length of the peripheral edge of each segment, which represents the length of the individual peripheral edge in which no chip groove is formed, y=1, 2, 3, … …, e, and a total of e segments, i.e.)>Indicating the total axial length of the single peripheral edge without chipbreakers.
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