微铣削中考虑刀具跳动的瞬时刀具挠度变形研究
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摘要
基于对将刀具跳动(包括轴线偏移跳动及轴线倾斜跳动)的影响考虑在内的微铣削力的研究,提出一种新的微铣削加工过程中刀具挠度变形解析计算方法,在微铣削加工刀具挠度变形理论模型的建立过程中,以微立铣刀为例,将微立铣刀假设为连续的铁木辛柯梁(Timoshenkobeam)并采用刀具工件切削接触区域内沿刀具切削刃方向作用于切削刃离散微元上的分布微铣削力载荷取代作用于刀尖位置的总微铣削力。此外,为获取微铣削加工过程中的刀具挠度变形具体数值,设计并搭建包括x轴及y轴两方向电容式传感器的测量系统,并通过实验对所提出的微铣削加工过程中考虑刀具跳动的刀具挠度变形理论模型进行对比验证和分析,验证所提出模型的正确性,并为进一步研究微铣削加工过程工件表面质量及参数优化提供理论依据。
According to the micro milling forces considering the influence of tool run-out(axial offset and tilt), a new mathematic method of tool deflections is proposed in the micro milling process. In the theoretical model of tool deflections in micro milling operations, the micro flat end mill is assumed as a continuous Timoshenko beam, and the distributed cutting forces acting on the discrete elements along the cutting edge direction have displaced the total cutting forces acting on the tool tip. Moreover, in order to obtain the values of tool deflections in micro milling operations, the measuring system including the capacitance sensors in the x-axis and y-axis directions is designed and set up. Then, the measured and predicted tool deflections can be compared and analyzed to validate the accuracy of the proposed theoretical model. The proposed model of tool deflections provides the theoretical foundation for further study on surface quality and parameters optimization of micro milling process.
According to the micro milling forces considering the influence of tool run-out(axial offset and tilt), a new mathematic method of tool deflections is proposed in the micro milling process. In the theoretical model of tool deflections in micro milling operations, the micro flat end mill is assumed as a continuous Timoshenko beam, and the distributed cutting forces acting on the discrete elements along the cutting edge direction have displaced the total cutting forces acting on the tool tip. Moreover, in order to obtain the values of tool deflections in micro milling operations, the measuring system including the capacitance sensors in the x-axis and y-axis directions is designed and set up. Then, the measured and predicted tool deflections can be compared and analyzed to validate the accuracy of the proposed theoretical model. The proposed model of tool deflections provides the theoretical foundation for further study on surface quality and parameters optimization of micro milling process.
引文
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[16]HUO D H,CHEN W Q,TENG X Y,et al.Modeling the influence of tool deflection on cutting force and surface generation in micro-milling[J].Micromachines,2017,8(6):188.
[17]MIJU?KOVI?G,KRAJNIK P,KOPA?J.Analysis of tool deflection in micro milling of graphite electrodes[J].The International Journal of Advanced Manufacturing Technology,2015,76(1-4):209-217.
[18]TIMOSHENKO S P X.On the transverse vibrations of bars of uniform cross-section[J].The London,Edinburgh,and Dublin Philosophical Magazine and Journal of Science,1922,43(253):125-131.
[2]聂强,黄凯,毕庆贞,等.微铣削中考虑刀具跳动的瞬时切厚解析计算方法[J].机械工程学报,2016,52(3):169-178.NIE Qiang,HUANG Kai,BI Qingzhen,et al.New mathematic method of calculating instantaneous un-deformed chip thickness with tool run-out in micro-end-milling[J].Journal of Mechanical Engineering,2016,52(3):169-178.
[3]SAFFAR R J,RAZFAR M R,ZAREI O,et al.Simulation of three-dimension cutting force and tool deflection in the end milling operation based on finite element method[J].Simulation Modeling Practice and Theory,2008,16(10):1677-1688.
[4]宋戈,李剑峰,孙杰.基于铣削力精确建模的工件表面让刀误差预测分析[J].机械工程学报,2013,49(21):168-175.SONG Ge,LI Jianfeng,SUN Jie.Analysis on prediction of surface error based on precision milling cutting force model[J].Journal of Mechanical Engineering,2013,49(21):168-175.
[5]SUTHERLAND J W,DEVOR R E.An improved method for cutting force and surface error prediction in flexible end milling systems[J].Journal of Engineering for Industry,1986,108(4):269-279.
[6]KIM G M,KIM B H,CHU C N.Estimation of cutter deflection and form error in ball-end milling processes[J].International Journal of Machine Tools and Manufacture,2003,43(9):917-924.
[7]RYU S H.An analytical expression for end milling forces and tool deflection using Fourier series[J].The International Journal of Advanced Manufacturing Technology,2012,59(1-4):37-46.
[8]RODRíGUEZ P,LABARGA J E.A new model for the prediction of cutting forces in micro-end-milling operations[J].Journal of Materials Processing Technology,2013,213(2):261-268.
[9]MAMEDOV A,LAZOGLU I.Machining forces and tool deflections in micro milling[J].Procedia CIRP,2013,8:147-151.
[10]MAMEDOV A,LAZOGLU I.Instantaneous tool deflection model for micro milling[J].The International Journal of Advanced Manufacturing Technology,2015,79(5-8):769-777.
[11]LI Z L,ZHU L M.Envelope surface modeling and tool path optimization for five-axis flank milling considering cutter runout[J].Journal of Manufacturing Science and Engineering,2014,136(4):041021.
[12]WAN M,ZHANG W H,DANG J W,et al.New procedures for calibration of instantaneous cutting force coefficients and cutter runout parameters in peripheral milling[J].International Journal of Machine Tools and Manufacture,2009,49(14):1144-1151.
[13]ZHANG X,EHMANN K F,YU T,et al.Cutting forces in micro-end-milling processes[J].International Journal of Machine Tools and Manufacture,2016,107:21-40.
[14]BISSACCO G,HANSEN H N,SLUNSKY J.Modelling the cutting edge radius size effect for force prediction in micro milling[J],CIRP Annals-Manufacturing Technology,2008,67(1):113-116.
[15]JUN M B G,GOO C,MALEKIAN M,et al.A new mechanistic approach for micro-end-milling force modeling[J],Journal of Manufacturing Science and Engineering,2012,134(1):011006-011015.
[16]HUO D H,CHEN W Q,TENG X Y,et al.Modeling the influence of tool deflection on cutting force and surface generation in micro-milling[J].Micromachines,2017,8(6):188.
[17]MIJU?KOVI?G,KRAJNIK P,KOPA?J.Analysis of tool deflection in micro milling of graphite electrodes[J].The International Journal of Advanced Manufacturing Technology,2015,76(1-4):209-217.
[18]TIMOSHENKO S P X.On the transverse vibrations of bars of uniform cross-section[J].The London,Edinburgh,and Dublin Philosophical Magazine and Journal of Science,1922,43(253):125-131.