钛合金微槽球头铣刀的铣削性能研究

Shihong Zhang, Hu Shi, Baizhong Wang, Chunlu Ma, Qinghua Li
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引用次数: 0

摘要

钛合金被广泛应用于各个领域,但钛合金材料的铣削加工往往会导致高铣削力、铣削温度升高和切屑附着等问题。因此,钛合金的可加工性面临着挑战。为了提高钛合金材料的铣削性能,本研究通过数学计算分析了铣刀表面的有效工作区域。我们在该区域设计了微凹槽,利用其减摩和耐磨特性来缓解上述问题。球头铣刀切削刃的有效工作区域是根据铣削量和铣刀与工件之间的安装位置计算得出的。通过观察贝壳的表面结构,提出并设计了应用于铣刀表面工作区域的微凹槽。基于铣削模拟和实验测试,讨论了铣刀表面微槽区域和主轴转速对铣削性能的影响。实验结果表明,微槽铣刀产生的切削力、铣削温度和切屑抗粘附性均优于传统铣刀。带有三个微槽的铣刀在不同的主轴转速下性能最佳。这是因为铣刀表面微凹槽的存在改善了摩擦状态,促进了铣削力的降低,同时微凹槽还起到了储存切屑的作用,减轻了切屑软化和附着在铣刀上的现象。使用带有三个微凹槽的铣刀进行切削试验时,铣削力降低了 10%至 30%,铣削温度降低了 10%至 20%,表面粗糙度降低了 8%至 12%。
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Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys
Titanium alloys are widely used in various fields, but milling titanium alloy materials often leads to problems such as high milling forces, increased milling temperatures, and chip adhesion. Thus, the machinability of titanium alloys faces challenges. To improve the milling performance of titanium alloy materials, this study analyzes the effective working area on the surface of the milling cutter through mathematical calculations. We design micro-grooves in this area to utilize their friction-reducing and wear-resisting properties to alleviate the aforementioned issues. The effective working area of the ball end milling cutter’s cutting edge is calculated based on the amount of milling and the installation position between the milling cutter and the workpiece. By observing the surface structure of seashells, micro-grooves are proposed and designed to be applied in the working area of the milling cutter surface. The impact of the micro-groove area on the milling cutter surface and spindle speed on milling performance is discussed based on milling simulation and experimental tests. Experimental results show that the cutting force, milling temperature, and chip resistance to adhesion produced by micro-groove milling cutters are superior to conventional milling cutters. Milling cutters with three micro-grooves perform best at different spindle speeds. This is because the presence of micro-grooves on the surface of the milling cutter improves the friction state, promoting a reduction in milling force, while the micro-grooves also serve as storage containers for chips, alleviating the phenomenon of chip softening and adhesion to the cutter. When conducting cutting tests with a milling cutter that has three micro-grooves, the milling force is reduced by 10% to 30%, the milling temperature drops by 10% to 20%, and the surface roughness decreases by 8% to 12%.
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