基于Abaqus的微铣刀几何结构参数优化

Parameter Optimization of Geometric Structure of Micro-Milling Tool Based on Abaqus

针对微细铣削加工过程的特点,建立了微铣刀结构模型并利用Pro E软件进行了微细铣刀的结构设计,采用Abaqus软件通过有限元仿真方法比较不同结构参数的微铣刀的模态及抗断裂强度,获得了各阶模态固有频率和振型,以及微铣刀结构上的应力分布情况与特点,分析了刃口直径为50μm微铣刀的刀具悬伸量及刀具尖端几何形状对刀具性能的影响,从而获得了适合加工的几何结构参数.通过聚焦离子束(FIB)方法制备了刃口直径为50μm的微铣刀,在不同基底材料上进行了微铣削加工实验研究,并通过扫描电子显微镜(SEM)高分辨率地观测并分析了铣削效果以及微铣刀的磨损情况,探讨了几何形状以及实际偏心量对刀具的影响并评价了不同几何形状微铣刀的性能.

Regarding the characteristics of micro-milling process,the micro-milling structural model was established and the tool structure was designed by Pro E software in this paper. The mode and fracture strength of micro-milling tools with different structural parameters were compared by finite element simulation with Abaqus software to obtain natural frequency and vibration mode of different orders mode,stress distribution and characteristics of micro-milling tools structure as well. The influence of tool overhang and geometric structure of micro-milling tool tip with the cutting edge diameter of 50 μm on the properties of tools was analyzed. Meanwhile,the geometric structural parameters were acquired which are suitable for processing. Finally,the micro-milling tools with cutting edge diameter of 50 μm were fabricated with focused ion beam（ FIB） method,and the micro-milling experiment was conducted on different materials as base. The cutting performance and the micro-milling tool abrasion were characterized with high resolution by scanning electron microscope（ SEM）. The influences of geometric structure and actual eccentricity on the tool performance were explored,and the performance of different geometric structures of micro-milling tools was evaluated.