Design and wear analysis of tool for high-efficiency disk milling roughing of aero-engine blisk channels

Abstract

As the core component of the aero-engine, the manufacture of blisk is difficult because of its materials belonging to difficult-to-machine materials and complex structure. One of the effective ways to solve the above problems is to apply the disk milling technology to the roughing of blisk channels, and the design of disk milling tool. The optimization of cutting parameters and the research of tool wear are of great significance to the advantage of the disk milling. Firstly, based on the mutual relationship between the tool groove and the insert, the mathematical model of geometric angle influencing cutting effect is established, and the main structures of tool are calculated and modeled. Secondly, the dynamic simulation analysis of the designed disk milling tool is carried out to optimize the structure of tool by comparing the change of stress, total deformation, and main cutting force. Then, the milling experiment is carried out to optimize the cutting parameters, which are further optimized by using response surface methodology and considering the cutting efficiency. Finally, under the optimized cutting parameters, the wear condition of the designed milling tool is studied by experiment, in order to provide a better theoretical reference and technical support for the blisk high-efficiency cutting and tool design.