Study on End Milling Generation Surface Model and Simulation in View of Main Axle's Tolerance

In accordance with the relative movement between end-milling cutter and workpiece surface, a theoretical generation model for milled surface was established with the movement error of principal axle considered. Then the milled surfaces under various cutting condition were simulated, the results of which showed that end milled surfaces were of "vaulted profile", heights of surface irregularty at various points to be different with maximum value in the middle and smaller at both sides, the difference were determined by diameter of milling cutter, feeding speed, ratio between the diameter of milling cutter and teeth point curve radius and width of workpiece. The study results can be applied to quality prediction of milled surfaces for precision and/or super precision milling operation.

Choice of reference surfaces for machined surface roughness in milling of SiC_p/Al composites

In order to choose the appropriate reference surface on the machined surface roughness of Si Cp/Al composites, the cutting experiments of Si Cp/Al composites were carried out, and the machined surface topography was measured by OLS3000 Confocal laser scanning microscope. The 3D measured data of machined surface topography were analyzed by the area power spectrum density. The result shows that the texture of machined surface topography in milling of Si Cp/Al composites is almost isotropic. This is the reason that the values of Rq at different locations on the same machined surface are obviously different. Through the comparison of performance of different filtering methods, the robust least squares reference surface can be used to extract the surface roughness of SiC p/Al composites effectively.

Milling Research and Tool Selection Design of SiC14Cu4Mg0.5Si based on Aluminium Matrix 2A14

The selection of milling tools for Si C14Cu4Mg0.5Si based on Aluminium matrix 2A14 was analyzed, and the factors that affect the efficiency of the milling were discussed. The Si C14Cu4Mg0.5Si was designed for use on the moon landing vehicle or missile wings, but the hardness of aluminium-silicon carbide composite material was very high, much higher than the general hardness of cemented carbide, which will bring many difficulties in the aluminium-silicon carbide composite material processing. The chemical compositions of Si C14Cu4Mg0.5Si were analyzed. A new selected indexable cutter was designed to mill Si C14Cu4Mg0.5Si. The structure design of milling cutter was different from the conventional milling cutter, breaking the previous limitations to a certain extent, pioneering the idea. The tool material wear was detected by experiments. The mechanical and physical properties of Si C14Cu4Mg0.5Si were also tested. Si C14Cu4Mg0.5Si exhibited different surface quality characteristics under different milling tools.

An integrated machine-process-controller model to predict milling surface topography considering vibration suppression

Surface topography is an important factor in evaluating the surface integrity and service performance of milling parts.The dynamic characteristics of the manufacturing system and machining process parameters significantly influence the machining precision and surface quality of the parts,and the vibration control method is applied in high-precision milling to improve the machine quality.In this study,a novel surface topography model based on the dynamic characteristics of the process system,properties of the cutting process,and active vibration control system is theoretically developed and experimentally verified.The dynamic characteristics of the process system consist of the vibration of the machine tool and piezoelectric ceramic clamping system.The dynamic path trajectory influenced by the processing parameters and workpiece-tool parameters belongs to the property of the cutting process,while different algorithms of active vibration control are considered as controller factors.The milling surface topography can be predicted by considering all these factors.A series of experiments were conducted to verify the effectiveness and accuracy of the prediction model,and the results showed a good correlation between the theoretical analysis and the actual milled surfaces.