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微细铣削加工是使用微型立铣刀在高主轴转速下制造微型元件的加工方式,分析切削力和加工稳定性对表征微细铣削加工过程起着重要的作用。提出一种数值分析的方法来研究螺旋齿球头立铣刀在可变径向切削深度下的微细铣削加工过程。首先建立了球头铣刀微细铣削的模型,并推导了切削力的计算公式;采用时域仿真的方法详细计算了螺旋齿球头立铣刀和平头立铣刀铣削加工的切削力,并对比了二者切削力仿真的结果;通过时域和频域研究相结合的方式详细分析了小径向切深下球头铣刀微细铣削的稳定性。最后,分析得到了Hopf-flip分岔,并深入对比和分析了不同加工条件下铣削加工的稳定性状况。
Micro milling is the machining method of micro-components using micro-end mills at high spindle speeds. Analysis of cutting forces and machining stability plays an important role in characterizing micro-milling processes. A numerical analysis method is proposed to study the fine milling process of helical ball end mill under variable radial cutting depth. Firstly, the model of fine milling of ball mill was established, and the calculation formula of cutting force was deduced. The cutting force of milling mill with helical ball mill end mill and flat end mill was calculated in detail by time domain simulation method. The simulation results of the two cutting forces are presented. The stability of the micro milling of the ball nose milling cutter with small radial depth is analyzed in detail by combining the time domain and the frequency domain research. Finally, the Hopf-flip bifurcation was analyzed, and the stability of the milling process under different processing conditions was deeply compared and analyzed.