考虑刀具变形的球头铣刀铣削力建模与仿真  

MODELING AND SIMULATION OF MILLING FORCES FOR FLEXIBLE BALL-END MILLING CUTTERS

作　　者：倪其民[1] 李从心[1] 吴光琳[1] 阮雪榆[1] 

机构地区：[1]上海交通大学国家模具CAD工程研究中心,上海200030

出　　处：《机械工程学报》2002年第3期108-112,共5页Journal of Mechanical Engineering

基　　金：教育部博士点基金资助项目(98024834)

摘　　要：提出了准确识别参与切削的切削刃段的实体造型方法；基于铣削力与切削负载之间的经验关系，建立了三分量的球头铣刀铣削力模型；通过将刀具简化为一个悬臂梁结构，给出了刀具变形计算公式；从刀具变形对刀齿切削路径影响的几何关系出发，推导了三维进给运动下的瞬时切厚表达式。在此基础上，开发了完整的球头铣刀三轴铣削过程铣削力仿真系统。仿真计算和试验结果表明了模型及算法的正确性。：Key techniques in modeling and simulation of cutting forces in ball-end milling process with a flexible cutter are studied. First, the idea to extract the chip geometry for general 3-axis ball-end milling operations, in the form of in-cut segments of the engaged edges, using solid modeling technique, is proposed. Then, on the basis of the empirical relationship between cutting forces and chip load, a three-component force model is developed. The calculation formula of deflection-dependent instantaneous chip thickness under three-dimensional cutter feed motion is devised in two steps. First, the cutter deflection is calculated, by modeling the ball-end milling cutter as a solid cantilever beam rigidly supported by the tool holder. Then, the expression of chip thickness is established by analyzing the effect of cutter deflection on the cutting path of cutter teeth. Based on the modeling and simulation techniques introduced, a simulation system for prediction of cutting forces in 3-axis ball-end milling process is developed. The applicability of the system is demonstrated through a typical instance. The simulation results show a very satisfactory agreement with those obtained by the experiments.

关 键 词：球头铣刀 铣削力 刀具变形 建模 仿真 

分 类 号：TG714[金属学及工艺—刀具与模具] TG54