钛合金高速铣削因具有高效率、高质量的优点,被广泛应用于航空航天制造业。为了研究高速铣削参数对钛合金高速铣削力的影响,利用专业金属切削加工有限元软件AdvantEdge,对TC4钛合金高速铣削过程进行二维模拟仿真,建立了高速铣削TC4钛合金时铣削力的预测模型,获得了不同铣削参数对铣削力的影响规律,并对仿真结果进行了试验验证。结果表明:高速铣削TC4钛合金的铣削力比较小,基本不超过100 N,铣削力最大值达到140 N;铣削合力对铣削宽度的变化最为敏感,对铣削速度和铣削深度变化的敏感次之,对每齿进给量最不敏感。研究结果为优化高速铣削工艺提供理论分析和试验依据。

High-speed milling of titanium alloy is widely used in aviation and aerospace industries for its high efficiency and good quality. To obtain the effect of high-speed milling parameters on milling force,two-dimensional simulation of TC4 titanium alloy high speed milling process was carried out by AdvantEdge,which was a professional metal-cutting processing finite element software. The milling force prediction model for high-speed milling of TC4 was built,and the effects of milling parameters on milling force were ob-tained. Experiments were conducted to verify the results. The results show that the milling force of high-speed milling of titanium alloy TC4 is relatively small,not exceeding 100 N,and the biggest milling force reaches 140 N. The milling force of high-speed milling for titanium is most sensitive to the variation of milling depth,secondarily sensitive to the variation of milling speed and milling width,and no sensitive to the variation of feed per tooth. The theoretical anal

碳纤维增强复合材料(CFRP)属于典型的难加工材料。通过改变加工工艺参数,使用硬质合金成型铣刀,研究了碳纤维复合材料成型槽铣削时铣削力随铣削速度和进给速度的变化关系,并分析了铣削出口表面的加工缺陷及其与铣削力的变化关系。试验结果表明:铣削力随铣削速度的升高而降低,随进给量的增大而减小;铣削出口处表面主要缺陷为撕裂、毛刺和材料未切断等,其中撕裂为主要缺陷且撕裂面积随铣削力的变大而增大。

Carbon Fiber Reinforced Plastic (CFRP)is a typically hard machining material. The changing relationship between the milling speed and feeding rate along with milling force was researched during milling forming slots of CFRP,by using the forming tool of carbon carbide with the different technological parameters in machining. The machining fault on exit surface of milling and its changing relationship in regard with milling force were analyzed. The experimental results have shown that the milling force is lowered with a higher milling speed,and is reduced with increasing of feeding rate. The fault of the exit surface of milling is mainly delamina-tion,burr and non-cutting off of materials,and the area of delamination is increased with getting higher of milling force.

航空发动机广泛采用钛合金薄壁结构,薄壁件在铣削加工过程中受铣削力的影响易于产生加工变形,影响加工质量。为减少加工变形,提高加工质量,需对铣削加工过程中的铣削力进行预测。为此,以Johnson-Cook本构方程为基础,考虑材料热力学动态性能和断裂准则对铣削力的影响,建立了基于加工特征的钛合金Ti-6Al-4V铣削力预测模型。首先,利用UG/Open工具模块对UG软件进行二次开发,创建了零件加工特征知识库。然后,利用Deform-3D仿真软件对材料本构模型、切屑分离和切屑断裂准则等进行描述,建立钛合金Ti-6Al-4V铣削加工有限元模型,对铣削力进行预测。铣削力实验证明了预测模型的可行性。最后,利用建立的有限元模型研究了工件曲率半径对铣削力的影响。结果表明,圆弧内轮廓铣削过程中的铣削力较大,圆弧外轮廓铣削过程中的铣削力较小。

Thin-walled structures with titanium alloy are widely used in aircraft engine .However , deflection induced by cutting force will reduce the finished part accuracy due to the lower rigidy of thin-walled structure .The amount of cutting force must be accurately predicted to improve the machining precision of thin-walled parts.A numerical prediction model for milling force of Ti-6Al-4V titanium alloy is developed based on the Johnson-Cook constitutive equation ,UG geometric modeling and Deform-3D fi-nite element simulation .The effects of the material properties and fracture criterion on the milling force are considered during sim -ulation modeling.Firstly,the knowledge-base of features for aero-engine components is created by UG software .Then,the finite el-ement model of milling process is established by modeling the material constitutive relationship ,chip fracture and material separa-tion criteria.The machining experiments are conducted to validate the feasibility of the proposed sim

为获得铣削速度v、背吃刀量ap、每齿进给量fz 和径向铣削深度ae 对铣削力的影响规律，利用TiAlN涂层刀具进行了高速铣削NAK80模具钢试验。结果表明，铣削力随着铣削速度的增加而减小，随背吃刀量的增大而增大，并随每齿进给量和径向铣削深度的增加而增加。在单因素试验结果的基础上，应用线性回归分析方法，建立了铣削力的回归数学预测模型。

In order to research the effect of milling parameters on milling forces by milling speed v, axial depth of milling ap , feed rates per tooth fz , and radial depth of milling ae , the high speed milling experi-ments on NAK80 die steel with TiAlN coated tools was carried out .The results showed that the milling force decreased with the rising of milling speed , per tooth feed and radial depth of milling , whlle in-creased with the axial depth of milling .On the basis of the single factor experiment results , the regres-sion prediction mathematics model for milling forces were established by linear regression analysis .

为预测铣削力，在ABAQUS／Explicit平台上建立了铣削加工物理仿真模型，以高速侧铣加工铝合金7050-T 7451槽腔为例，仿真了铣削力，并与实验结果进行了对比。结果表明仿真铣削力与实际铣削力误差最大为20.89％，认为仿真模型可以代替大量的切削实验来获得不同加工参数和刀具参数下的铣削力。

To detect the forces in milling ,a finite element model is established on ABAQUS/Explicit platform .The forces for aluminum alloy 7050-T7451 in high speed milling pocket are simulated and compared with the test results .It shows that the maximum error is 20 .89% and the simulation model can be a substitute for a lot of experiments with different cutting parameters and tool parameters .