整体硬质合金螺旋立铣刀磨槽工艺优化

Optimization of Solid Carbide End Mill in Flute Grinding Process

分析立铣刀生产各工序所用工时发现磨槽工序是生产瓶颈,而影响磨槽生产效率和产品质量的主要因素为砂轮粒度、进给量f和砂轮线速度v。以槽表面粗糙度和加工效率为优化目标,进行三因素三水平正交试验,优选出最佳参数,而后对优选参数进行磨槽质量稳定性测试。结果表明,砂轮粒度对槽表面粗糙度影响最大,最优参数为砂轮粒度D46,f=100mm/min、v=25m/min。采用该参数进行批量生产,磨槽质量稳定。从批量生产的立铣刀中随机抽样进行切削试验,从被加工表面纹路、表面粗糙度以及刀具寿命三方面与优化前生产的立铣刀进行对比,结果表明两者无明显差别。采用优选的切削参数,在保证性能稳定的前提下,可使磨槽效率提升10%,经济效益明显。

The working hours of each procedure used in the production of the solid carbide end mill are analyzed and found that the grinding groove procedure is the bottle neck. The main affective factors of less efficiency and quality are the grain size,the feed rate f and the circular linear speed v of the grinding wheel. Taking the surface roughness and machining efficiency as the optimization objective,the optimized parameters are selected with the orthogonal experiments of three factors and three levels. The stability of flute grinding is tested with the optimized parameters. The results show that the grain size of the grinding wheel has the greatest influence on the surface roughness of the groove. The optimum parameters of the grinding wheel are grain size D46,feed rate f = 100 mm/min and the circular linear speed v = 25 m/min. The optimized parameters are used in mass production and the quality of grinding groove is steady. The cutting experiments are carried out by random sampling from batch end mill. The results have no obvious difference from the machined one before optimization in surface lines,surface roughness and tool life of the end mill. With the optimized parameters,the efficiency of the grinding groove can be raised by 10%,and the economic benefit is obvious with a stable quality.