重庆理工大学学报2025，Vol.39Issue(11)：175-182,8.DOI:10.3969/j.issn.1674-8425(z).2025.06.021
刃口参数对钛合金超高速铣削刀具性能及寿命的影响
Study on the influence of cutting edge parameters on tool performance and life in ultra high speed milling of titanium alloy
摘要
Abstract
Titanium alloys are increasingly used in consumer electronics such as mobile phones and computers,prompting manufacturers to adopt ultra-high-speed milling(UHSM)technology to enhance processing efficiency.However,machining under high spindle speeds(up to 8 000 r/min)and large feed rates(up to 4 500 mm/min)significantly accelerates tool wear,leading to reduced tool life and increased manufacturing costs.This paper aims to optimize cutting edge parameters-including chamfer angle(γl),land width(br),and edge radius(rc)—to improve cutting performance and prolong tool life during UHSM of titanium alloys. First,the effects of edge parameters on cutting force and temperature are analyzed.Smaller chamfer angles increase cutting resistance due to reduced effective contact area,which elevates cutting temperatures and accelerates tool wear.Larger land widths enhance force dispersion and heat dissipation,while excessively large edge radii increase cutting forces by expanding contact areas.Conversely,overly small edge radii cause stress concentration,leading to edge chipping.To quantify these relationships,a series of simulation experiments are designed using a three-factor,three-level response surface methodology(RSM),with parameters as follows:land width(0.05～0.15 mm),chamfer angle(-15°～-5°),and edge radius(0.005～0.025 mm).The simulation model,based on the Johnson-Cook constitutive model and implemented in Advantage software,considers workpiece dynamic deformation,thermal conduction,and thermo-mechanical coupling.Calibration experiments on a DMU70V machining center validate the model,with cutting force errors within 15％compared to experimental measurements. Simulation results show significant variations in cutting performance:the X-direction cutting force ranges from 220 N to 282 N(a 28.1％difference),and cutting temperature varies from 898 ℃ to 1 345 ℃(a 49.8％difference).Through regression analysis,the optimal edge parameters are determined as br=0.10 mm,γl=-10°,and rc=0.015).GU20F carbide tools are then fabricated with edge passivation(achieving a 3～4 μm radius)and a 2～3 μm TiSiN coating to enhance wear resistance. Cutting performance tests on a FANUC ROBODRILL α-T21iFb machine under UHSM conditions(8 000 r/min spindle speed,4 500 mm/min feed rate,0.50 mm depth of cut)demonstrate the optimized tools reduce X-direction cutting force by 8.1％(from218.9 N to 201.2 N)and Y-direction force by 10.3％(from 153.4 N to 137.6 N).Tool life experiments show the optimized tools process an average of 526 workpieces,up by 5.3％compared with unoptimized tools(500 workpieces). This paper explores the influence of cutting edge parameters on UHSM performance,providing a validated framework for parameter optimization through simulation and experiment.The optimized tools markedly improve cutting efficiency and tool durability,addressing critical challenges in high-speed manufacturing of titanium alloy components for the electronics industry.The findings may provide some valuable theoretical and technical insights into tool design in high-speed machining of difficult-to-cut materials,promoting more efficient and cost-effective manufacturing.关键词
超高速铣削加工/刃口参数优化/切削性能/刀具寿命Key words
ultra high speed milling processing/optimization of cutting edge parameters/cutting performance/tool life分类
机械制造引用本文复制引用
陈曦,孙健哲,赵景波,王奇,何亚峰,郭魂..刃口参数对钛合金超高速铣削刀具性能及寿命的影响[J].重庆理工大学学报,2025,39(11):175-182,8.基金项目
国家自然科学基金项目(62273061,52405453,52305446) （62273061,52405453,52305446）
常州市基础研究计划项目(CJ20235067) （CJ20235067）
江苏自然科学基金面上项目(BK20211061) （BK20211061）
江苏省高等学校基础科学研究面上项目(24KJD460001) （24KJD460001）
航空发动机高性能制造工业与信息化部重点实验室(西北工业大学)开放课题(HPM-2022-01) （西北工业大学）
