Abstract
In this paper, a revolving cycloid milling cutter was designed with a larger effective cutting helix angle and rake angle than a ball end milling cutter of the same diameter. This new type of milling cutter can solve the problems of low machining efficiency, severe tool wear, and low surface quality in titanium alloy processing. A comparison of the cutting performance of titanium alloys processed by the revolving cycloid milling cutter and the ball end milling cutter was carried out to obtain the variation laws of the cutting force and the processing surface quality under different tool wear conditions. The result shows that the wear zone of the revolving cycloid milling cutter is shallow and wide compared to that of the ball end milling cutter. As the wear speeds up, the spoon-shaped wear gathering zone found in the ball end milling cutter does not happen with the revolving cycloid milling cutter. The revolving cycloid milling cutter can significantly lower the axial force, the tangential force, and the ratio of the axial force to the tangential force with a stable cutting process.
Highlights
Featuring high specific strength, high creep corrosion resistance, and high wear resistance, titanium alloy has been extensively used in the fields of aviation, aerospace, energy, and biomedical science [1].small tool–chip contact area, large unit cutting force, and high cutting temperature might be caused in the cutting process due to the physical properties of titanium alloy, like low thermal conductivity, small elastic modulus, and large friction coefficient
A cycloid rotates around the center of the cutter to form the profile processing titanium alloy parts
By means of numerical simulation and comparison, we showed that the helical angle
Summary
High creep corrosion resistance, and high wear resistance, titanium alloy has been extensively used in the fields of aviation, aerospace, energy, and biomedical science [1]. Carried out a test study on titanium alloy milling with respect to the inclination angle of the ball end milling cutter and obtained the influence law of milling method on the cutting force, tool wear, and its surface integrity. When machining small-curvature surfaces for aviation structure parts, the cutting efficiency of a ball end milling cutter is low, the tool wear is serious, and the surface quality of the workpiece is poor. Compared with the ball end milling cutter, the revolving cycloid milling cutter [23] presents a stable cutting process, a sharper cutting edge, and even wear on the tool for small-curvature surfaces in the aviation structure parts cutting process due to its large helix angle and working rake angle in actual cutting, presenting certain advantages in cutting performance. The cutting performance of the revolving cycloid milling cutter was evaluated
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