铝合金拐角铣削的犁耕效应研究

Investigation on Plough Effect of Corner Milling of Aluminum Alloy

小圆角铝合金型腔是航空常用的典型结构件,但其切削加工的颤振问题导致表面质量恶化、刀具损坏并且制约制造效率和质量。利用极坐标投影方法,计算典型铝合金材料铣削加工中的实时侵入面积以及切削抗力,建立考虑犁耕效应的颤振预估模型。计算结果表明,相对于传统上固定主轴转速的叶瓣图分析法,该模型可以针对进给变速和主轴变速两个方面考虑对铝合金铣削加工中的拐角激励颤振效应进行了分析及实验验证。实验结果表明,该模型与实际测得的切削值线性拟合度较高,能有效地预测拐角处颤振,为加工参数选择提供重要参考。

The small corner cavity is a typical structure in aeronautical parts. The chattering caused by cutting machining would result in damage to surface of cutting tool, and hence reducing the feed rate and cutting quality. In this work, the real-time invading area and cutting resistance were investigated based on polar coordinates projection method,and a chattering budget model, in which the plough effect is taken into account, was developed. It is shown that the resulting model can be used to analyze the corner chattering effect generated by cutting machining of aluminum alloy by considering together, compared to the traditional fixed spindle speed lobes diagram. The experimental studies demonstrated that this model is consistent with the actual case, and it can be used to predict the practical chattering at corner. This model provides an alternative reference for parameter selection during machining process.