钛合金盘铣开槽刀具的优化设计

Tool Optimization Design of Disc Milling Grooving with Titanium Alloy

为了提高整体叶盘的加工效率,将盘铣应用于该类零件的开槽粗加工。相比于插铣和侧铣工艺,盘铣能将该类零件开槽加工效率提高3-4倍。由于盘铣刀直径大、齿数多,切削过程中容易产生振动,加剧刀具磨损,因此刀具结构对表面质量和加工效率有较大影响。针对盘铣刀铣削过程中承受大载荷、高抗力、易磨损等情况,对盘铣刀做了铣削过程仿真及刀具优化设计。对不同尺寸的整体叶盘,设计了三种不同参数的盘铣刀;利用ANSYS软件对三种不同参数的盘铣刀进行模态分析,结果表明,盘铣刀的固有频率与激励频率差距较大,盘铣刀产生的变形与磨损非常小。对三种不同参数的盘铣刀进行了铣削过程的静态受力分析,结果表明,Φ200和Φ400的盘铣刀的最大应力分布于刀片与刀体结合处,Φ600的盘铣刀的最大应力分布于键槽处,刀具的最大变形量为0.48mm,说明盘铣刀的刚性完全满足加工要求;通过盘铣刀磨损试验,验证仿真分析的可信度。

In order to improve the processing efficiency,disc milling is first used in the grooving rough machining of blisk.The processing efficiency can be improved 3-4 times compared to plunge milling and side milling when disc milling is adopted.However,the disc cutter diameter is big,and the number of tool teeth is more,so the vibration is easily to generated during machining,which aggravates tool wear.The tool structure has an important effect on surface quality and processing efficiency.The simulation of disc milling grooving is carried out,and the structure optimization of disc cutter is conducted.Three different size disc cutters are designed,which are applied to the different size blisk.The modal analysis of disc cutter is carried out,and the results show that there is a significant difference between inherent frequency and excitation frequency,so the tool wear and tool deformation resulted by these factors are very little.The static analysis of disc cutter is studied,for the disc cutter with the diameter of 200mm and 400mm respectively,the maximum stress distributes at the juncture of the blade and the cutter body.For the disc cutter with the diameter of 600mm,the maximum stress distribute at the key point,the maximum deformation of disc cutter is 0.48mm,which certify that the stiffness of disc cutter meets the machining requirements.The reliability of simulation analysis is proved by tool wear experiment.