Abstract
Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.
Highlights
High creep corrosion resistance, and high wear resistance, titanium alloy has been extensively used in aviation, aerospace, energy and biomedical fields [1]
The physical properties like low thermal conductivity, small elastic modulus and large friction coefficient of titanium alloy may lead to small tool-chip contact area, large unit cutting force, and high cutting temperature in the cutting process [2,3,4,5,6], seriously restricting the machining quality and application of titanium alloy parts
The titanium alloy workpiece surface is complex and diverse, but the variety of cutting tools is single, which leads to the unreasonable application of cutting tools and prominent failure problem
Summary
The physical properties like low thermal conductivity, small elastic modulus and large friction coefficient of titanium alloy may lead to small tool-chip contact area, large unit cutting force, and high cutting temperature in the cutting process [2,3,4,5,6], seriously restricting the machining quality and application of titanium alloy parts. The titanium alloy workpiece surface is complex and diverse, but the variety of cutting tools is single, which leads to the unreasonable application of cutting tools and prominent failure problem. In order to improve processing efficiency and reduce manufacturing costs, it is imperative to develop new cutting tools. Liu et al [7] studied the optimization of the edge shape optimization of the radius-end milling cutter to greatly enhance the machining efficiency of the radius-end milling cutter. Jin et al Reference [8]
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