CN109648125B - Multi-tooth design method capable of realizing alternate cutting of left-handed cutting edge and right-handed cutting edge - Google Patents

Multi-tooth design method capable of realizing alternate cutting of left-handed cutting edge and right-handed cutting edge Download PDF

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CN109648125B
CN109648125B CN201910075656.2A CN201910075656A CN109648125B CN 109648125 B CN109648125 B CN 109648125B CN 201910075656 A CN201910075656 A CN 201910075656A CN 109648125 B CN109648125 B CN 109648125B
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王福吉
贾振元
王泽刚
张博宇
赵猛
成德
卢晓红
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Dalian University of Technology
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Abstract

The invention belongs to the technical field of cutting processing of difficult-to-process materials, and relates to a micro-tooth design method capable of realizing alternate cutting of a left-handed cutting edge and a right-handed cutting edge. The design method can be applied to milling cutters with different diameters, helical angles and blade numbers and can ensure the designed cutting mode. Therefore, the micro-tooth design method has good universality and engineering application value, and can finally realize high-speed, stable and effective processing of the carbon fiber composite material under large cutting consumption.

Description

Multi-tooth design method capable of realizing alternate cutting of left-handed cutting edge and right-handed cutting edge
Technical Field
The invention belongs to the technical field of cutting processing of composite materials, and relates to a multi-tooth design method capable of realizing alternate cutting of left and right cutting edges.
Background
The composite material has the performance advantages of high specific strength, light weight, strong bearing capacity and the like, and is widely applied to modern industrial development. However, the composite material belongs to a typical difficult-to-machine material, and due to the material characteristics of anisotropy and heterogeneity, the matching property of the existing metal milling cutter and the material is poor, particularly for the upper surface layer fiber and the lower surface layer fiber, the out-of-plane side of the metal milling cutter is not restricted by the material, damage such as burrs, tearing and the like is easily generated under the action of axial force, the machining quality requirements of the upper surface layer fiber and the lower surface layer fiber are difficult to guarantee at the same time, and therefore the service performance of the component is reduced.
In order to solve the problems of burrs and tearing on the surface layer in the high-speed milling of the composite material, research needs to be carried out on the action mode of the cutter structure and the material, so that the existing cutter structure is improved and innovated. In the prior art, cutting edges with left-handed rotation and right-handed rotation are designed on a peripheral edge of a milling cutter, and the staggered left-handed and right-handed cutting edges alternately cut in the milling process, so that the generation of surface fiber burrs and tearing can be inhibited. However, this milling cutter has integral cutting edges, and the radial and normal cutting forces of the solid edge milling cutter are large during milling, resulting in low milling stability, fast cutting edge wear, and difficult tool life improvement.
In addition, a multi-tooth milling cutter enables a plurality of left-screw and right-screw spiral grooves to be designed on the peripheral edge, so that dense micro cutting units are formed on the peripheral edge, the cutting effect of replacing grinding with milling is achieved, the surface machining quality can be improved, and layering and burr damage in the machining process are inhibited. For example, patent No. cn101623778.a discloses a whole hard alloy fish scale milling cutter, wherein a fish scale micro cutting unit of a peripheral edge of the whole hard alloy fish scale milling cutter consists of a left-handed cutting edge and a right-handed cutting edge which are symmetrically staggered, the length of a main cutting edge of each cutting unit is 0.05mm-1mm, and the micro cutting unit can reduce the cutting width in the milling process, so that the cutting force is effectively reduced, and the stability of the milling process is improved. However, in the prior art research, the effective cutting part of the multi-tooth milling cutter cannot realize a left-right alternating cutting mode in any section. If the machining mode that the left-handed cutting edge and the right-handed cutting edge cut alternately can be ensured on the multi-tooth milling cutter, the cutting effect of replacing grinding by milling can be realized, the milling resistance is reduced, and the milling efficiency is improved; the shearing effect on the surface layer fiber can be ensured, the generation of burrs and tearing of the surface layer fiber can be inhibited, and the service life of the cutter is prolonged.
Disclosure of Invention
The invention aims to solve the problem of inhibiting burrs and tearing damages on the surface layer of the high-performance carbon fiber composite material during high-speed milling so as to improve the processing quality of the carbon fiber composite material and prolong the service life of a cutter. Therefore, the invention provides a multi-tooth design method capable of realizing alternate cutting of left and right rotating cutting edges. The key structural parameters are calculated by determining the structural corresponding relation between the micro-teeth of the milling cutter, so that the structural geometric relation of the multi-tooth milling cutter meets the processing mode of alternately cutting a right-handed cutting edge and a left-handed cutting edge, the generation of damage such as surface burrs, tearing and the like can be effectively inhibited by the processing mode of alternately cutting, the processing quality of the carbon fiber composite material can be effectively improved, the accuracy of the multi-tooth design method is verified based on three-dimensional modeling software, and high-speed, stable and effective processing of the carbon fiber composite material under large cutting consumption is guaranteed.
The technical scheme of the invention is as follows:
a multi-tooth design method capable of realizing alternate cutting of left and right cutting edges is characterized in that a three-dimensional milling cutter is split along the axial direction and then unfolded, an effective cutting part representing a cutting mode is selected, a two-dimensional milling cutter micro-tooth local graph taking the tangential X and the axial Z as coordinate systems is formed, a right-hand spiral groove and a left-hand chip dividing groove are staggered to form micro-teeth, and the micro-teeth comprise right-hand cutting edges and left-hand cutting edges; milling cutter design process, cutter geometric parameters: the edge width of the right-handed cutting edge is g1Width g of left-handed chip separating groove2Spiral angle theta of right-hand spiral groove, spiral angle β of left-hand chip separation groove and number Z of right-hand spiral grooves1The number of grooves Z of the left-handed chip separating groove2And a milling cutter diameter D; other intermediate variables: p is the height of the left-hand cutting edge; q is the height of the right-handed cutting edge; h is the height between two adjacent micro-teeth in the X direction and an intermediate parameter g; the specific design method comprises the following steps:
step 1: the method ensures that no 'blank cutting' phenomenon exists in the continuous cutting process, namely the distance between two adjacent micro-teeth of the same cutting edge in the Z direction is 0 and needs to be met;
g2cosθ＝g1cosβ[1]
step 2: in the continuous cutting process, the alternating cutting of the right-handed cutting edge and the left-handed cutting edge is realized, namely the height q of the right-handed cutting edge is equal to the height p of the left-handed cutting edge and is equal to the height h between two adjacent micro teeth in the X direction, namely p is q is h;
(I) the height q of a right-handed cutting edge is h;
Figure GDA0002362776340000031
Figure GDA0002362776340000032
when Z is2>Z1The method comprises the following steps:
Figure GDA0002362776340000033
when Z is2<Z1The method comprises the following steps:
Figure GDA0002362776340000034
(II) the height p of the left-handed cutting edge is h;
Figure GDA0002362776340000035
Figure GDA0002362776340000036
when Z is2>Z1The method comprises the following steps:
Figure GDA0002362776340000041
when Z is2<Z1The method comprises the following steps:
Figure GDA0002362776340000042
and step 3: simultaneous equations [2] [3] [4] [6] [7] [8 ]:
when Z is2>Z1The method comprises the following steps:
Figure GDA0002362776340000043
simultaneous equations [2] [3] [5] [6] [7] [9 ]:
when Z is2<Z1The method comprises the following steps:
Figure GDA0002362776340000044
and 4, step 4: will find Z2Substituting into formula [3]Find g2G is mixing2Substituting into formula [1]I.e. find g1And finally, importing the four parameters determining the cutting mode into a three-dimensional software model, and verifying the accuracy of the method.
The invention has the beneficial effects that the multi-tooth design method capable of realizing the alternate cutting of the left-handed cutting edge and the right-handed cutting edge on the multi-tooth cutter is invented, when the carbon fiber composite material is milled, the burrs and the tearing on the surface layer are important factors influencing the processing quality of the milling CFRP, and how to effectively inhibit the generation of the burrs and the tearing becomes a hotspot of the current research. The multi-tooth design method can meet the requirement of a machining mode that the left-handed cutting edge and the right-handed cutting edge can be cut alternately on any milling cutter section, has relative stability during cutting of a micro cutting unit, and prolongs the service life of a cutter. Therefore, the design method can meet the high-quality and high-efficiency processing requirements of carbon fiber composite parts with different fiber grades, different thicknesses and multiple layering modes.
Drawings
FIG. 1 is a computational flow diagram of a multi-tooth design method;
FIG. 2 is a two-dimensional partial schematic view of a multi-tooth left-hand and right-hand cutting edge cutting in an alternating fashion;
FIG. 3 is a two-dimensional cutter of embodiment 1;
fig. 4 is a two-dimensional tool of example 2.
In the figure: 1, a right-handed spiral groove; 2, left-handed chip separation grooves; 3 micro teeth; 4, a right-handed cutting edge; 5 left-handed cutting edge; g1The edge width of the right-hand cutting edge 4; g2The width of the left-handed chip-separating groove 2, the helical angle of the theta right-handed helical groove 1, the helical angle of the β left-handed chip-separating groove 2 and the Z1The number of right-handed spiral grooves; z2Number of left-handed flutes. D, the diameter of the milling cutter; q the height of the right-hand cutting edge 4; p height of the left-hand cutting edge 5; h is the height between two adjacent microteeth 3 in the X direction.
Detailed Description
The following detailed description of the embodiments of the invention is provided in connection with the accompanying drawings and the claims.
In this embodiment, the accuracy of the method for designing the micro-teeth and the reliability of the milling quality of the milling cutter are verified from two tool diameters D being 10mm and D being 6 mm.
In the first embodiment, the diameter D of the milling cutter is 10mm, the spiral angle θ of the right-handed spiral groove 1 is 15 °, the spiral angle β of the left-handed chip separation groove 2 is 35 °, and the number Z of the right-handed spiral grooves1The width of the right-handed cutting edge 4 is g as 121Width g of left-handed chip breaker 22Number of left-handed flutes Z2(ii) a The specific design method comprises the following steps:
step 1: the method ensures that no 'blank cut' phenomenon exists in the continuous cutting process, namely the distance between two adjacent upper and lower micro teeth of the same cutting edge is 0, and needs to be met;
g2cos15＝g1cos35[1]
step 2: in the continuous cutting process, the left-handed cutting edge 5 and the right-handed cutting edge 4 are cut alternately, namely p is q is h;
the height q of the right-handed cutting edge 4 is h;
Figure GDA0002362776340000051
Figure GDA0002362776340000052
when Z is2>And when 12:
Figure GDA0002362776340000053
when Z is2<And when 12:
Figure GDA0002362776340000061
(II) the height p of the left-handed cutting edge 5 is h;
Figure GDA0002362776340000062
Figure GDA0002362776340000063
when Z is2>And when 12:
Figure GDA0002362776340000064
when Z is2<And when 12:
Figure GDA0002362776340000065
and step 3: simultaneous equations [2] [3] [4] [6] [7] [8 ]:
when Z is2>And when 12:
Z2＝18[10]
simultaneous equations [2] [3] [5] [6] [7] [9 ]:
when Z is2<And when 12:
Z2＝6[11]
and 4, step 4: will Z2Substitution of 18 into equation [3]Can obtain g2＝0.7148mm，g10.8428mm, and introducing the structural parameters of the cutter into a model, wherein a milling cutter two-dimensional diagram is shown in FIG. 3, and the requirements of no free cutting in the Z direction and X are metAnd a machining mode of alternately cutting the left-handed cutting edge 5 and the right-handed cutting edge 4. (Z)2The parameter obtained 6 is introduced into the model so that the right-handed helical groove 2 is too small to facilitate chip removal and is therefore discarded).
In the second embodiment, the diameter D of the milling cutter is 6mm, the spiral angle θ of the right-handed spiral groove 1 is 15 °, the spiral angle β of the left-handed chip separation groove 2 is 35 °, and the number Z of right-handed spiral grooves1The width of the right-handed cutting edge 4 is g 101Groove width g of the left-hand spiral groove 22Number of left-handed flutes Z2(ii) a The specific design method comprises the following steps:
step 1: ensuring that no 'blank cut' phenomenon exists in the continuous cutting process, namely the requirement is met;
g2cos15＝g1cos35[1]
step 2: in the continuous cutting process, the left-handed cutting edge 5 and the right-handed cutting edge 4 are cut alternately, namely, p is q is h;
the height q of the right-handed cutting edge 4 is h;
Figure GDA0002362776340000071
Figure GDA0002362776340000072
when Z is2>When 10, the process:
Figure GDA0002362776340000073
when Z is2<When 10, the process:
Figure GDA0002362776340000074
(II) the height p of the left-handed cutting edge 5 is h;
Figure GDA0002362776340000075
Figure GDA0002362776340000076
when Z is2>When 10, the process:
Figure GDA0002362776340000077
when Z is2<When 10, the process:
Figure GDA0002362776340000078
and step 3: simultaneous equations [2] [3] [4] [6] [7] [8 ]:
when Z is2>When 10, the process:
Z2＝15[10]
simultaneous equations [2] [3] [5] [6] [7] [9 ]:
when Z is2<When 10, the process:
Z2＝5[11]
and 4, step 4: will Z215 into equation [3 ═]Can obtain g2＝0.5146mm，g1When the tool configuration parameters are introduced into the model at 0.6069mm, the milling cutter bidimensional diagram satisfies the machining mode of the Z-direction non-cutting blank and the X-direction left-handed cutting edge 5 and right-handed cutting edge 4 alternately cutting as shown in fig. 4. (Z)2The parameter obtained 5 is introduced into the model so that the right-handed helical flute 1 is too small to facilitate chip removal and is therefore discarded).
The multi-tooth design method for realizing the alternate cutting of the left-handed cutting edge and the right-handed cutting edge on the multi-tooth milling cutter can take the complex geometric structure of the multi-edge milling cutter into consideration, so that the fibers on the upper surface layer and the lower surface layer are ensured to be subjected to the alternate cutting action of the left-handed cutting edge and the right-handed cutting edge. The method is simple in calculation, reliable in result and good in engineering application prospect.

Claims (1)

1. A multi-tooth design method capable of realizing alternate cutting of left and right rotating cutting edges, namely a three-dimensional milling cutterThe cutting method comprises the following steps of splitting along the axial direction, then expanding, selecting an effective cutting part representing a cutting mode, forming a two-dimensional milling cutter micro-tooth local graph taking the tangential X and the axial Z as a coordinate system, forming micro-teeth (3) by staggering a right-handed spiral groove (1) and a left-handed chip dividing groove (2), wherein the micro-teeth (3) comprise a right-handed cutting edge (4) and a left-handed cutting edge (5); milling cutter design process, cutter geometric parameters: the edge width of the right-handed cutting edge (4) is g1The groove width g of the left-handed scrap separating groove (2)2The spiral angle theta of the right-handed spiral groove (1), the spiral angle β of the left-handed chip separation groove (2) and the number Z of the right-handed spiral groove (1)1The number Z of the left-handed scrap separating groove (2)2And a milling cutter diameter D; other intermediate variables: p is the height of the left-handed cutting edge (5); q is the height of the right-handed cutting edge (4); h is the height between two adjacent micro-teeth (3) in the X direction and a middle parameter g; the method is characterized by comprising the following specific steps:
step 1: the method ensures that no 'blank cutting' phenomenon exists in the continuous cutting process, namely the distance between two adjacent micro-teeth (3) of the same cutting edge in the Z direction is 0, and the requirement is met;
g2cosθ＝g1cosβ[1]
step 2: in the continuous cutting process, the right-handed cutting edge (4) and the left-handed cutting edge (5) are cut alternately, namely the height q of the right-handed cutting edge (4) is equal to the height p of the left-handed cutting edge (5) and is equal to the height h between two adjacent microteeth (3) in the X direction, namely p is q is h;
the height q of the right-handed cutting edge (4) is h;
Figure FDA0002424620240000011
Figure FDA0002424620240000012
when Z is2>Z1The method comprises the following steps:
Figure FDA0002424620240000013
when Z is2<Z1The method comprises the following steps:
Figure FDA0002424620240000014
(II) the height p of the left-handed cutting edge (5) is h;
Figure FDA0002424620240000021
Figure FDA0002424620240000022
when Z is2>Z1The method comprises the following steps:
Figure FDA0002424620240000023
when Z is2<Z1The method comprises the following steps:
Figure FDA0002424620240000024
and step 3: when Z is2>Z1The method comprises the following steps:
simultaneous equations [2] [3] [4] [6] [7] [8 ]:
Figure FDA0002424620240000025
when Z is2<Z1The method comprises the following steps:
simultaneous equations [2] [3] [5] [6] [7] [9 ]:
Figure FDA0002424620240000026
and 4, step 4: when Z is2>Z1The method comprises the following steps: will find Z2Substituting into formula [4]Find g2；
When Z is2<Z1The method comprises the following steps: will find Z2Into the formula [5]Find g2；
G is prepared from2Substituting into formula [1]I.e. find g1The four parameters Z which ultimately determine the cutting mode1、Z2、g1、g2And (4) importing the data into a three-dimensional software model, and verifying the accuracy of the method.
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