高速铣削光学级SiCp/Al复合材料的铣削力预测

Prediction of milling forces in high-speed milling optical grade SiCp/Al composites

在顺铣和逆铣两种条件下,为了对比研究金刚石粒度为32μm的PCD单齿立铣刀高速铣削光学级SiCp/Al复合材料时铣削力变化特性,针对铣削方式和铣削用量对铣削力特性的影响进行了研究,并基于多元线性回归分析方法建立了铣削力的经验公式。采用L9(34)正交实验方案进行高速铣削实验,使用旋转测力仪采集各铣削力信号,研究了顺铣和逆铣两种条件下铣削用量对铣削力特性的影响,并采用多元线性回归分析方法建立了切向力Ft、径向力Fr、轴向力Fz和总铣削力Ftotal的经验公式。实验结果表明:所建立的铣削力的经验公式回归显著性较高,且模型平均误差在10%之内。两种铣削条件下对各铣削力影响水平最高的是轴向切削深度,其次是每齿进给量和切削速度。顺铣时Ft,Fr和总铣削力Ftotal均高于逆铣,而Fr相差不大。

Under the conditions of down and up milling,to compare the variation characteristics of milling forces of a polycrystalline-diamond single-tooth end mill with a diamond grain size of 32μm when milling optical-grade SiCp/Al composites at high speed,the effects of the milling method and milling amounts on milling forces characteristics were studied.The empirical formulae of milling forces were also established based on a multiple linear regression analysis method.An L9(34)orthogonal cutting experiment was con⁃ducted to study the influence of milling amounts on the cutting force under the two conditions.A rotary dy⁃namometer was then used to collect the signals of each milling force,and an empirical formula of tangential force Ft,radial force Fr,axial force Fz,and total milling force Ftotal was then established using the multiple linear regression analysis method.Experimental results demonstrated that the milling force calculated us⁃ing the established regression formula was significantly high,and the average error of the model was within 10%.Under the two milling conditions,the highest level of influence on each milling force was the axial cutting depth,followed by the feed per tooth and cutting speed.To obtain smaller cutting forces,a small⁃er axial cutting depth should first be selected,followed by a smaller feed per tooth and a higher cutting speed.