基于运动学的高速高精密铣削力建模：综合模型与试验
收稿日期: 2022-04-07
修回日期: 2022-04-24
录用日期: 2022-06-10
网络出版日期: 2022-09-22
基金资助
国家重点研发计划(2018YFB1703200)
Modeling of high speed and high precision milling forces based on kinematics: Comprehensive modeling and experimental
Received date: 2022-04-07
Revised date: 2022-04-24
Accepted date: 2022-06-10
Online published: 2022-09-22
Supported by
National Key Technology Research and Development Program of China(2018YFB1703200)
高速高精密铣削加工中铣削力是最重要的过程参量之一，铣削力信息的准确反馈对保证加工过程中的稳定性具有十分重要的意义。然而，影响铣削力大小的因素有很多种，目前缺乏一种考虑多种因素下的综合铣削力模型。因此，着重研究并综合考虑了刀具磨损、刀具跳动、刀具弹性变形对瞬时切削厚度的影响，同时分析了弹性变形对刀具切入与切出角的影响规律，改进了刀具瞬时切削厚度模型。基于运动学分析，将切削刃位置与预加工工件形态相互统一，建立了综合铣削力模型。为验证所提出综合模型的精确性和通用性，进行铣削实验，实验结果表明，铣削力预测值与实验值吻合较好，铣削力误差值小于1%，并通过分析刀具磨损与铣削力之间的相互变化关系，得出进给方向上的铣削力与Z向的铣削力系数对刀具磨损的影响最大。因此，切向力分量以及Z向的铣削力系数的变化特征可以较好的表征刀具磨损状况，从而提高铣削加工精度和效率。
李刚 , 张宇 , 李斯 , 朱锟鹏 . 基于运动学的高速高精密铣削力建模：综合模型与试验[J]. 航空学报, 2023 , 44(8) : 427261 -427261 . DOI: 10.7527/S1000-6893.2022.27261
The milling force is one of the most important process parameters in high speed and high precision milling process. Accurate feedback of milling force information is very important to ensure the stability and precision of milling process. However， there are many factors that affect the milling force， and there is currently a lack of a comprehensive milling force model that considers multiple factors. Therefore， this paper focuses on research and comprehensively considers the influence of tool wear， tool run-out， and tool elastic deformation on the instantaneous undeformed cutting thickness. Furthermore， the relationship between elastic deformation and variety of entry and exit angles for each engaged flute is analyzed， and the instantaneous cutting thickness model is improved. Based on the kinematic analysis， the position of cutting edge is unified with the shape of premachined workpiece， and a comprehensive model of high speed milling force is established. To verify the accuracy and generality of the proposed model， a series of milling experiments under different parameters are carried out. The experimental results show that the predicted value of milling force is in good agreement with the experimental value， and the error value of milling force is less than 1%. By analyzing the relationship between tool wear per tooth and milling force， it is concluded that the milling force in the feed direction has the greatest impact on the tool wear. Therefore， the radial force component can well characterize the tool wear， so as to improve the milling accuracy and efficiency.
Key words： comprehensive model; tool run-out; tool wear; elastic deformation; kinematics
| 1 | DIKSHIT M K， PURI A B， MAITY A，et al. Determining cutting force coefficients from instantaneous cutting forces in ball end milling［J］. International Journal of Machining and Machinability of Materials，2016，18（5/6）：552. |
| 2 | YOON H S， EHMANN K F. Dynamics and stability of micro-cutting operations［J］. International Journal of Mechanical Sciences，2016，115-116：81-92. |
| 3 | NOURI M， FUSSELL B K， ZINITI B L，et al. Real-time tool wear monitoring in milling using a cutting condition independent method［J］. International Journal of Machine Tools and Manufacture，2015，89：1-13. |
| 4 | ZHAO Z M， LIU X L， YUE C X，et al. Time-varying analytical model of ball-end milling tool wear in surface milling［J］. The International Journal of Advanced Manufacturing Technology，2020，108（ 4）：1109-1123. |
| 5 | CHEN W Q， HUO D H， TENG X Y，et al. Surface generation modelling for micro end milling considering the minimum chip thickness and tool runout［J］. Procedia CIRP，2017，58：364-369. |
| 6 | DAVIM J P. Modern mechanical engineering：Research，development and education［M］. London：Springer Science & Business Media，2014：115-120. |
| 7 | ZHU K P， ZHANG Y. Modeling of the instantaneous milling force per tooth with tool run-out effect in high speed ball-end milling［J］. International Journal of Machine Tools and Manufacture，2017，118-119：37-48. |
| 8 | LI H Z， WU B. Development of a hybrid cutting force model for micro milling of brass［J］. International Journal of Mechanical Sciences，2016，115-116：586-595. |
| 9 | SINGH K K， KARTIK V， SINGH R. Stability modeling with dynamic run-out in high speed micromilling of Ti6Al4V［J］. International Journal of Mechanical Sciences，2019，150：677-690. |
| 10 | AFAZOV S M， RATCHEV S M， SEGAL J. Modelling and simulation of micro-milling cutting forces［J］. Journal of Materials Processing Technology，2010，210（ 15）：2154-2162. |
| 11 | LI J L， CAI X J， AN Q L，et al. A hybrid approach for cutting force prediction in flank milling based on analytical and 3D finite element method［J］. The International Journal of Advanced Manufacturing Technology，2020，110（ 5）：1601-1613. |
| 12 | JALILI SAFFAR R， RAZFAR M R， ZAREI O，et al. Simulation of three-dimension cutting force and tool deflection in the end milling operation based on finite element method［J］. Simulation Modelling Practice and Theory，2008，16（ 10）：1677-1688. |
| 13 | WOJCIECHOWSKI S， MATUSZAK M， POWA?KA B，et al. Prediction of cutting forces during micro end milling considering chip thickness accumulation［J］. International Journal of Machine Tools and Manufacture，2019，147：103466. |
| 14 | BUDAK E， OZLU E， BAKIOGLU H，et al. Thermo-mechanical modeling of the third deformation zone in machining for prediction of cutting forces［J］. CIRP Annals，2016，65（ 1）：121-124. |
| 15 | 董永亨，李淑娟，李言，等. 基于改进Z-MAP算法的球头铣刀加工表面形貌仿真与试验研究［J］. 机械工程学报，2017，53（ 23）：197-208. |
| DONG Y H， LI S J， LI Y，et al. Simulation and experimental study of ball-end milling surface topography based on an improved Z-MAP algorithm［J］. Journal of Mechanical Engineering，2017，53（23）：197-208 （in Chinese）. | |
| 16 | JIA Z Y， GE J， MA J W，et al. A new cutting force prediction method in ball-end milling based on material properties for difficult-to-machine materials［J］. The International Journal of Advanced Manufacturing Technology，2016，86（9）：2807-2822. |
| 17 | LU X H， JIA Z Y， WANG X X， et al. Three-dimensional dynamic cutting forces prediction model during micro-milling nickel-based superalloy［J］. The International Journal of Advanced Manufacturing Technology， 2015， 81（ 9）：2067-2086. |
| 18 | WAN M， WEN D Y， MA Y C，et al. On material separation and cutting force prediction in micro milling through involving the effect of dead metal zone［J］. International Journal of Machine Tools and Manufacture，2019，146：103452. |
| 19 | LI G， QU D， FENG W W，et al. Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout［J］. The International Journal of Advanced Manufacturing Technology，2016，87（1）：1193-1202. |
| 20 | XIAN C， SHI Y Y， LUO J，et al. Milling force modeling for disc milling cutter of indexable three-sided inserts considering tool runout［J］. The International Journal of Advanced Manufacturing Technology，2021，115（7）：2191-2204. |
| 21 | ZHANG X W， EHMANN K F， YU T B，et al. Cutting forces in micro-end-milling processes［J］. International Journal of Machine Tools and Manufacture，2016，107：21-40. |
| 22 | SAHOO P， PRATAP T， PATRA K. A hybrid modelling approach towards prediction of cutting forces in micro end milling of Ti-6Al-4V titanium alloy［J］. International Journal of Mechanical Sciences，2019，150：495-509. |
| 23 | ZHANG X， PAN X D， WANG G L，et al. Tool runout and single-edge cutting in micro-milling［J］. The International Journal of Advanced Manufacturing Technology，2018，96（1）：821-832. |
| 24 | ZHANG X W， YU T B， WANG W S. Prediction of cutting forces and instantaneous tool deflection in micro end milling by considering tool run-out［J］. International Journal of Mechanical Sciences，2018，136：124-133. |
| 25 | BAI Y， JIA Z Y， FU R，et al. Mechanical model for predicting thrust force with tool wear effects in drilling of unidirectional CFRP［J］. Composite Structures，2021，262：113601. |
| 26 | DUCROUX E， FROMENTIN G， VIPREY F，et al. New mechanistic cutting force model for milling additive manufactured Inconel 718 considering effects of tool wear evolution and actual tool geometry［J］. Journal of Manufacturing Processes，2021，64：67-80. |
| 27 | SUN Y J， SUN J， LI J F，et al. Modeling of cutting force under the tool flank wear effect in end milling Ti6Al4V with solid carbide tool［J］. The International Journal of Advanced Manufacturing Technology，2013，69（9）：2545-2553. |
| 28 | ZHOU L， DENG B， PENG F Y，et al. Analytical modelling and experimental validation of micro-ball-end milling forces with progressive tool flank wear［J］. The International Journal of Advanced Manufacturing Technology，2020，108（9）：3335-3349. |
| 29 | OLIAEI S N B， KARPAT Y. Influence of tool wear on machining forces and tool deflections during micro milling［J］. The International Journal of Advanced Manufacturing Technology，2016，84（9）：1963-1980. |
| 30 | 岳彩旭，都建标，姜男，等. 考虑后刀面磨损及过缝冲击的拼接模具铣削力建模与实验研究［J］. 振动与冲击，2019，38（17）：284-291. |
| YUE C X， DU J B， JIANG N，et al. Modeling and experimental research on milling force of splicing die considering rear face wear and slit impact［J］. Journal of Vibration and Shock，2019，38（17）：284-291 （in Chinese）. | |
| 31 | FU Z T， YANG W Y， WANG X L，et al. An analytical force model for ball-end milling based on a predictive machining theory considering cutter runout［J］. The International Journal of Advanced Manufacturing Technology，2016，84（9）： 2449-2460. |
| 32 | BAO W Y， TANSEL I N. Modeling micro-end-milling operations. Part I：analytical cutting force model［J］. International Journal of Machine Tools and Manufacture，2000，40（15）：2155-2173. |
| 33 | 郭松. 刀具磨损引起的工件加工误差建模与补偿技术研究［D］. 南京：南京航空航天大学，2012：8-19. |
| GUO S. Research on modeling and compensation of machining error induced by tool wear［D］. Nanjing：Nanjing University of Aeronautics and Astronautics，2012：8-19 （in Chinese）. | |
| 34 | 袁美霞. 微径球头铣刀铣削微小结构加工精度影响机制研究［D］. 北京：北京理工大学，2016：17-47. |
| YUAN M X. Research on machining precision of micro structure milled by microdiameter ball end milling cutter［D］. Beijing：Beijing Institute of Technology，2016：17-47 （in Chinese）. | |
| 35 | ZHU Z R， YAN R， PENG F Y，et al. Parametric chip thickness model based cutting forces estimation considering cutter runout of five-axis general end milling［J］. International Journal of Machine Tools and Manufacture，2016，101：35-51. |
| 36 | SUN C， ALTINTAS Y. Chatter free tool orientations in 5-axis ball-end milling［J］. International Journal of Machine Tools and Manufacture，2016，106：89-97. |
| 37 | GERMAIN D， FROMENTIN G， POULACHON G，et al. From large-scale to micromachining：a review of force prediction models［J］. Journal of Manufacturing Processes，2013，15（3）：389-401. |
| 38 | BUDAK E， ALTINTAS Y， ARMAREGO E. Prediction of milling force coefficients from orthogonal cutting date［J］. Journal of Manufacturing Science and Engineering，1996，118 （2）：216-224. |
/
| 〈 |
|
〉 |
CJA