Abstract
Cr12MoV die steel is a typical high-strength and high-hardness material. Because of the high hardness of Cr12MoV die steel, which is approximately 50–65 HRC after quenching, and the tool’s weak rigidity, cutting vibration, and tool deformation are inevitable during the cutting process. In this paper, a model for predicting the surface topography of a convex curved die steel machined by a ball-end milling cutter was established. In addition, the surface springback of the workpiece is considered. According to the surface characteristics of the convex curved workpiece, the vector algorithm and transformation matrix are applied to calculate the milling cutter motion trajectory equation. Then, the influence of dynamic factors on the tool path is calculated, and finally the surface topography of the workpiece is simulated through the Z-map model. The simulation error of three-dimensional surface roughness Sa at different positions of the curved surface is between 10% and 16%. After considering the dynamic factors, the simulation error is reduced by about 50%.
Highlights
Auto panel dies generally use Cr12MoV and 7CrSiMnMoV tool steels, which have a hardness of approximately 50–65 HRC after quenching
The effects of cutting vibration and tool deformation on the surface topography are considered in the model, and the established model is verified by experiments
During the milling process of convex curved die steel, the contact relationship between the tool and the workpiece is different at different positions of the curved surface, which can be regarded as the change process of the inclination angle λ of the tool along the feed direction
Summary
Auto panel dies generally use Cr12MoV and 7CrSiMnMoV tool steels, which have a hardness of approximately 50–65 HRC after quenching. Yao et al [5] has studied the surface topography during high-speed milling of TB6 What they found is that the feed per tooth has the greatest influence on the surface roughness, followed by the width of cut. Lavernhe et al [16] considers the actual edge geometry of the cutting tool to establish a more accurate surface topography simulation model, which simulates the surface flaws during the five-axis milling process and predicts the local flaws of the machined surface accurately. There are cutting vibration, tool wear, and springback of the workpiece surface in the actual milling process, which have a great impact on the surface topography, so it is meaningful to establish a surface topography simulation model that fully considers the machining errors. The simulation results are compared with the experiment data to verify the simulation results and analyze the mechanism of surface topography
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