Tool inclination angle designing for low-deformation and high-efficiency machining of thin-wall blade based on edge-workpiece-engagement

IF 3.5 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology Pub Date : 2024-08-02 DOI:10.1016/j.precisioneng.2024.07.015

Dongju Chen , Shuiyuan Wu , Jianqiang Wu , Ri Pan , Jinwei Fan , Yuhang Tang

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引用次数: 0

Abstract

The maximum flexibility direction(MFD) is solved for establishing the deformation estimation criterion of the blade during machining process, and the larger the milling force in MFD, the bigger the deformation of the blade during machining process. A new milling force calculation algorithm based on edge-workpiece-engagement(EWE) is proposed by analyzing the contact process between the ball-end milling tool and the chip. The chip thickness of each tool element of each edge curve at any rotation angle is calculated, the milling force of MFD and SLDs under different inclination angles are calculated. The average absolute milling force in MFD reaches the minimum value of 0.65126N when the lead/tilt angle is 30°/-45°, and the maximum machining efficiency is reached when the lead/tilt angle is 45°/-45°.The optimized tool inclination angle, which is 30°/-45° for lead/tilt angle, is obtained by solving the multi-objective optimization problem of machining deformation represented by relative deformation and machining efficiency represented by relative stable machining area. The effectiveness of the proposed scheme is verified by comparison of simulation and experiment for blade machining error under two kinds of tool orientations.

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基于刃口与工件啮合的薄壁叶片低变形高效加工刀具倾角设计

最大柔性方向（MFD）的求解用于建立加工过程中刀片的变形估计准则，MFD 中的铣削力越大，加工过程中刀片的变形也越大。通过分析球端铣刀与切屑的接触过程，提出了一种新的基于边缘-工件-啮合（EWE）的铣削力计算算法。计算了任意旋转角度下每条刃口曲线上每个刀元的切屑厚度，并计算了不同倾角下 MFD 和 SLD 的铣削力。通过求解以相对变形量为代表的加工变形和以相对稳定加工面积为代表的加工效率的多目标优化问题，得到了优化后的刀具倾角，即倾角为 30°/-45°。通过对两种刀具方向下叶片加工误差的仿真和实验对比，验证了所提方案的有效性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology 工程技术-工程：制造

CiteScore

7.40

自引率

5.60%

发文量

177

审稿时长

46 days

期刊介绍： Precision Engineering - Journal of the International Societies for Precision Engineering and Nanotechnology is devoted to the multidisciplinary study and practice of high accuracy engineering, metrology, and manufacturing. The journal takes an integrated approach to all subjects related to research, design, manufacture, performance validation, and application of high precision machines, instruments, and components, including fundamental and applied research and development in manufacturing processes, fabrication technology, and advanced measurement science. The scope includes precision-engineered systems and supporting metrology over the full range of length scales, from atom-based nanotechnology and advanced lithographic technology to large-scale systems, including optical and radio telescopes and macrometrology.