不等前角变螺旋圆弧立铣刀瞬时铣削力建模与系数标定方法  

Instantaneous Milling Force Modeling and Coefficient Calibration Method of Variable Helical Circular-arc End Mills with Unequal Rake Angle

作　　者：齐书韬 李佳奇 郑书材 徐金亭 孙玉文[1] QI Shutao;LI Jiaqi;ZHENG Shucai;XU Jinting;SUN Yuwen(School of Mechanical Engineering,Dalian University of Technology,Dalian,Liaoning,116024)

机构地区：[1]大连理工大学机械工程学院,大连116024

出　　处：《中国机械工程》2025年第4期681-687,696,共8页China Mechanical Engineering

基　　金：国家自然科学基金(U22A20202)。

摘　　要：不等前角变螺旋立铣刀可有效抑制加工颤振,提高加工表面质量,并可有效降低刀具崩刃风险,然而,因各齿刀刃几何参数各异,现有模型已难以实现其切削力的准确预测,为此,提出了不等前角变螺旋圆弧立铣刀的切削力精确建模与系数标定新方法。给出了变螺旋圆弧立铣刀切削刃的几何及位置关系表达式,建立了考虑刀具跳动和各齿刃形变化的瞬时未变形切屑厚度计算模型和微元切削力预测模型;提出了切削力系数与跳动参数并行标定的非线性优化方法,并基于线性最小二乘法及斜角切削理论给出了模型参数初值的高效求解算法。实验结果表明,切削力预测的幅值与波形与实测结果具有很好的一致性,预测误差在15%以内,验证了所提方法的有效性。Variable helical end mills with unequal rake angle maight effectively suppress milling chatters,which significantly improved the machined surface quality and simultaneously reduced the risk of tool breakages,however,due to the unequal geometric parameters of each cutting edge,the existing models had difficulty to accurately predict the cutting forces,hence,a new instantaneous milling force modeling and coefficient calibration method were proposed.Firstly,the geometry and position relational expression of the cutting edges for variable helical circular-arc end mills were given,then considering the tool runout and variation of geometrical parameters of cutting edges,an instantaneous uncut chip thickness calculation and element cutting force prediction model was established;Subsequently,a nonlinear optimization method to simultaneously calibrate the cutting force coefficients and tool runout parameters was proposed,and an efficient algorithm for solving the model parameter initial values was also given based on linear least squares and oblique cutting theory.The experimental results show that the amplitude and waveform of predicted cutting forces are consistent with the measured ones with errors of less than 15%,verifying the effectiveness of the proposed model.

关 键 词：不等前角 变螺旋铣刀 侧铣 铣削力 切削力系数辨识 

分 类 号：TH161[机械工程—机械制造及自动化]