Optimization of Hard Milling Processing for Convex Surface Joining Die with Milling Force Control
-
摘要: 机械加工对于模具结构的要求日益复杂,导致在模具自由型面上存在大量沟槽、凸凹等结构,容易出现磨损严重、拉毛拉裂等问题。对于模具不同位置所需要的应力特征不同,多采用镶块式模件拼接后整体铣削加工。而拼接处存在铣削力的突变导致刀具磨损过快和型面精度不高问题。本文通过阐述球头刀铣削凸曲面拼接模具表面形成机理,分析了铣削过程中不同位置的刀具-工件的接触关系;并且以球头铣刀加工不同硬度的淬硬钢Cr12MoV凸曲面拼接模具试验为对象,揭示切削深度、切削速度、每齿进给量及刀具铣削方向对拼接处铣削力突变的影响规律;以铣削力突变最小为目标进行正交试验研究,得到考察指标的主次影响规律和最优参数组合。Abstract: In machining for mold structural requirements become more complex, resulting in the existence of a large number of grooves and convex concave structure in the free type mold surface, prone to severe wear and galling cracking. The stress characteristics of different positions of the die are different, adopting the whole milling process of insert type module after splicing. However, the splicing is mainly caused by the milling force mutation, which leads to the problem of high tool wear and low precision. In this paper, the forming mechanism of the surface of the convex surface splicing die is formed by the tool of the ball end milling, and the contact relationship between the cutting tool and the workpiece in the milling process is analyzed; The hardened steel Cr12MoV convex surface splicing die experiment of ball end milling cutter of different hardness as the object, to reveal the effects of depth of cut, cutting speed, feed per tooth and milling directions on milling force mutation of splicing area. The orthogonal experiment was carried out with the minimum milling force mutation as the target, then the primary and secondary influence law and the optimal parameter combination were obtained.
-
Key words:
- convex surface /
- splicing die /
- multiple hardness /
- milling force mutation /
- experiments
-
[1] 张华禹.我国快速经济模具发展现状及发展建议[J].电加工与模具,2010,(S):38-40 Zhang H Y. Present situation and development suggestion of rapid economic die development in China[J]. Electromachining & Mould, 2010,(S):38-40(in Chinese) [2] 向红英.拉延模型面采用镶块拼接的原因分析[J].西华大学学报(自然科学版),2006,25(3):44-45,50 Xiang H Y. Analysis of the reasons for the usage of inlays block splicing in drawing die profile[J]. Journal of Xihua University (Natural Science), 2006,25(3):44-45,50(in Chinese) [3] 周科年,张国光.分块拼接大型冲裁模的介绍具J].模具工业,1900,(6):29-30 Zhou K N, Zhang G G. The introduction of the large punching die for the block stitching[J]. Die & Mould Industry, 1900,(6):29-30(in Chinese) [4] 虞耀君,马明亮,丁志华.汽车模具先进制造技术现状与行业发展趋势[J].制造技术与机床,2010,(5):45-47 Yu Y J, Ma M L, Ding Z H. Advanced manufacturing technology and development of automobile die[J]. Manufacturing Technology & Machine Tool, 2010,(5):45-47(in Chinese) [5] Dewes R C, Aspinwall D K. A review of ultra high speed milling of hardened steels[J]. Journal of Materials Processing Technology, 1997,69(1-3):1-17 [6] Chinchanikar S, Choudhury S K. Effect of work material hardness and cutting parameters on performance of coated carbide tool when turning hardened steel:an optimization approach[J]. Measurement, 2013,46(4):1572-1584 [7] 张臣,周来水,余湛悦,等.基于仿真数据的数控铣削加工多目标变参数优化[J].计算机辅助设计与图形学学报,2005,17(5):1039-1045 Zhang C, Zhou L S, Yu Z Y, et al. Multi-objective and varying parameter optimization of machining parameters based on NC simulation data[J]. Journal of Computer-Aided Design & Computer Graphics, 2005,17(5):1039-1045(in Chinese) [8] Umbrello D, Hua J, Shivpur R. Hardness-based flow stress and fracture models for numerical simulation of hard machining AISI 52100 bearing steel[J]. Materials Science and Engineering:A, 2004,374(1-2):90-100 [9] 丁云鹏.面向汽车覆盖件模具铣削工艺过程优化研究[D].哈尔滨:哈尔滨理工大学,2016 Ding Y P. Research on the optimazation of milling process of automobile panel dies[D]. Harbin:Harbin University of Science and Technology, 2016(in Chinese) [10] 吴俊谦.拼接淬硬钢球头铣削力建模仿真及试验研究[D].杭州:浙江工业大学,2011 Wu J Q. Modeling simulation and testing on ball-end milling of jointed hardened steels[D]. Hangzhou:Zhejiang University of Technology, 2011(in Chinese) [11] 庞俊忠,王敏杰,段春争,等.高速铣削P20和45淬硬钢的切削力[J].中国机械工程,2007,18(21):2543-2546 Pang J Z, Wang M J, Duan C Z, et al. Cutting forces in high speed milling of hardened steel P20 and 45[J]. China Mechanical Engineering, 2007,18(21):2543-2546(in Chinese) [12] 岳彩旭,刘献礼,史红,等.模具钢Cr12MoV硬态铣削过程切削力的研究[J].工具技术,2013,47(12):13-16 Yue C X, Liu X L, Shi H, et al. Research on cutting force in process of hard milling die steel Cr12MoV[J]. Tool Engineering, 2013,47(12):13-16(in Chinese) [13] 仲昭楠.模具钢Cr12MoV凸曲面铣削表面质量研究[D].哈尔滨:哈尔滨理工大学位,2016 Zhong Z N. Convex surface quality in milling process of mould steel Cr12MoV[D]. Harbin:Harbin University of Science and Technology, 2016(in Chinese) [14] Sasahara H, Obikawa T, Shirakashi T. Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models[J]. International Journal of Machine Tools and Manufacture, 2004,44(7-8):815-822 [15] 方开泰,马长兴.正交与均匀试验设计[M].北京:科学出版社,2001 Fang K T, Ma C X. Orthogonal and uniform experimental design[M]. Beijing:Science Press, 2001(in Chinese)
点击查看大图
计量
- 文章访问数: 242
- HTML全文浏览量: 24
- PDF下载量: 7
- 被引次数: 0