考虑刀具跳动和非对称磨损的微铣削工件表面形貌模型

Simulation Model of Workpiece Surface Morphology ConsideringAsymmetric Tool Wear

刀具跳动与非对称刀具磨损对微铣削工件表面形貌具有显著影响,在充分考虑这一影响因素基础上建立包含刀具跳动和非对称磨损的微铣削工件表面形貌模型,以精准预测微铣削工件表面切削形貌。基于余摆线运动方程研究刀具跳动和非对称性磨损对切屑负载的影响,构建切屑负载模型;根据最小切削厚度和弹性恢复理论,探索切屑负载和刀具磨损对工件底面切削残留高度的作用,并结合切屑负载模型建立包含刀具跳动和非对称磨损的底面切削形貌模型;提出底面形貌模型的三维点云仿真算法。实验结果表明,模型的预测误差在10%~15%,证明该模型能够精准预测微铣削工件底面的切削形貌。

Tool runout and the resulting asymmetric tool wear have an extremely significant effect on the surface profile of micro-milled workpieces.This influence factor is fully considered and a micro-milled workpiece surface topography model including tool runout and asymmetric wear to accurately predict the surface cutting topography of micro-milled workpieces is established.The effect of asymmetry of tool runout and wear on chip load is studied based on the residual cycloid equation of motion,and a chip load model is constructed.The role of chip load and tool wear on the cutting residual height of the bottom surface of the workpiece according to the minimum chip thickness and elastic recovery theory is explored,and a bottom surface cutting morphology model including tool runout and asymmetric wear by combining the chip load model is established.A three-dimensional point cloud simulation algorithm for the bottom surface morphology model is proposed.The 3D point cloud simulation algorithm of the bottom surface morphology model is proposed and experimentally verified,and the prediction error of the model is 10%~15%,which can accurately predict the cutting morphology of the bottom surface of the micro-milled workpiece.