Abstract
The damping performance of unequal tooth milling cutters is controlled by the pitch parameters. How to improve the vibration damping and dynamic balance of milling cutters needs to be further studied. This paper analyzes the pitch angle through the stability of the lobe diagram and the spectral characteristics, and unequal-pitch end mills with asymmetric structure were determined to have better cutting stability. Due to the principle error of the asymmetrical tool, dynamic balance accuracy is poor. The dynamic balance of the tool is analyzed, and the centroid model of the tool is established. In order to improve the dynamic balance accuracy of tools, the parameters of the groove shape are analyzed and optimized, and balance accuracy is improved. Through modal and milling-force analysis, the relative vibration displacement and cutting force of the optimized tool were reduced by 17% and 10%, respectively, which determined that such tools have better dynamic performance. Here, unequal tooth end mills could reduce vibration and had higher accuracy in dynamic balance by adjusting the parameters of the pitch angles and chip pockets, so that the tool could have higher cutting stability.
Highlights
When the speed was as high as 10,000 r/min, the balance accuracy of the tool could still reach G2.5, and this shows that the optimized tool meets the design requirements for dynamic balance accuracy
The dynamic performance of the machining system determines the degree of vibration; the dynamic balance of the tool is closely related to the dynamic performance of the system, resulting in the cutter unbalance directly affecting the evolution trend of the milling vibration
Analyzing the end-mill groove optimization method determined that the tool profile was optimized on the basis of the minimal eccentricity criterion, so that e0 = 150 um was reduced to e’0 = 3 um, which achieved the tool design criterion of dynamic balance accuracy
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Jin [7,8] developed dynamic models of unequal-pitch cutters by analyzing machining stability, and optimized the structure of the cutters and cutting parameters in the milling process. Chen [10] analyzed the influence of tool geometry parameters on the cutting process by the 3D modeling of unequal-pitch end mills. This paper combines stability and dynamic balance analysis of unequal tooth end mills to determine the structural parameters of the end mill, and the centroid model of the tool is established. The vibration reduction effect of asymmetric milling cutters is evaluated, and the chip flute parameters of milling cutters are optimized by improving the accuracy of dynamic balance This can theoretically alleviate chatter, meet the dynamic balance accuracy in actual processing, the centrifugal force is reduced, and cutting stability is further improved
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