主轴-切削交互过程建模与高速铣削参数优化

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The reasonable selection of high-speed cutting parameters is an obstacle in industry. The conservative cutting parameters limit the performance of high-speed machine tool and productivity. Focusing on high-speed milling process, a dynamic model of the high-speed spindle cutter system is given based on Timoshenko beam and Jones＇ bearing model with consideration of centrifugal force and gyroscopic moments. Dynamic properties of the spindle-cutter system are coupled with high-speed milling process, and then the interaction mechanism between the dynamic properties of the high-speed spindle cutter system and the machining process is investigated. The characteristic equation of the closed-loop dynamic milling system is derived. Based on the above theoretical analysis, an optimization method of cutting parameters based on the model of spindle-process interaction is proposed. The proposed optimization method is applied in the machining of the front face of a helicopter gear box cover, which is made of Aluminum. The axial depth of cut and spindle speed are chosen optimally, and the machining efficiency of the lateral wall on the front face of the gear box cover is increased 275%.高速切削参数的合理选择是困扰企业的一个难题，过于保守的切削用量限制了高速机床性能的发挥和生产效率的提高。以高速铣削加工为对象，考虑高速旋转主轴的离心力和陀螺力矩效应，基于Timoshenko梁单元和Jones轴承模型建立高速主轴．刀具系统动力学模型。将主轴．刀具动态特性与高速铣削过程耦合，研究高速主轴．刀具系统动力学特性与切削过程之间交互机理，推导闭环动态铣削系统的特征方程。基于上述理论分析，提出基于主轴．切削交互过程模型的高速铣削切削参数优化方法，并应用于某型直升机的铝合金变速箱端盖加工中，通过选用最佳切削深度和主轴转速，使变速箱盖前端面内侧壁的加工效率提高了275％。