Abstract
During high speed milling hardened steel, the problem that tool vibration reducing machining surface quality causes led to a research for the influence characteristics of milled surface topography through high speed milling experiment. To determine the formation condition of milled surface topography, using displacement increment of origin of tool coordinate system which is caused by the milling cutter vibration and installation error, modifies the cutting motion trajectory. Based on the tool-workpiece contact relationship and the cutting layer parameters of contact points on two teeth, the residual units of machined surface are established, thereby proposing a solution method for the deformation and distribution characteristic of residual units under the overhanging volume and the vibration. Therefore, the milled surface topography of cutting hardness steel with high speed ball-end milling cutter is revealed to bring out a striking contrast between the simulation and experiment of milled surface topography of hardness steel.
Highlights
High speed ball-end milling cutter is a typical high speed milling cutter tool and widely used in finishing surface of automobile large-size hardened steel molds [1, 2]
Aiming at the above problems existing in high speed milling of hardened steel, this paper studies the influencing characteristics of cutter vibration on the milled surface topography through an experiment of high speed milling of hardened steel with two experiment schemes, and conducts a research on the forming process of high speed milling machined surface, establishes the simulation model of milled surface topography under the cutter vibration
Based on the formulation results, we evaluated the above process schemes through the residual unit height of milled surface topography and the uniformity coefficient of unit distribution
Summary
High speed ball-end milling cutter is a typical high speed milling cutter tool and widely used in finishing surface of automobile large-size hardened steel molds [1, 2]. The surface hardness of hardened steel is over HRC55, there will be larger elastic recovery and the tool vibration is under high speed milling This milled surface quality deterioration of hardened steel has been a key problem that mold manufacturing enterprises need to be addressed [3,4,5]. The above method cannot efficiently control the formation process of high speed milling surface which milled surface topography exist diversity and uncertainty, thereby dissatisfying requirement of high efficiency machining large precision molds. During the progress of machining the hardened steel mold with the high-speed ball-end mill having diameter of 20mm, the machined surface quality of hardened steel, the machining efficiency of process scheme and the process effect are as shown in Table 1 and Fig. The milled surface topography changes with cutter vibration, thereby aggravating contradiction between the milling efficiency and the machined surface quality
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