Simulation of high-speed machining processes by multi-edge mills

Abstract

Based on the results of the numerical experiment by finite element analysis (FEA) the mill design having the initial tooth profile in the form of a trapezoid located along two intersecting spiral lines with angles of inclination of 14 and 71 degrees. As a result, about 70 cutting protrusions – are formed on the cylindrical surface, i.e., the total number of cutting edges in the cutting dynamics can be up to 280 blades. A model and methods for determining the geometric and kinematic parameters of cutting milling the required shape, dimensions and quality of the surface of the detail are proposed. The roughness at optimal cutting modes correspond to the Ra = 1.25-0.63 μm, which is comparable to grinding processing. The shape of individual chip elements can be described as spherical, its dimensions do not exceed 20 μm, and larger chip agglomerates have submicron and nanostructural fragmentation. Due to the increase of edges on the surface of new design mill increase the efficiency and intensity of deformation processes too (the number of single cutting cycles is up to 4000-6000 s-1). This is also in good agreement with the numerical estimates by the FEA method.