Cutting Dynamics Research on the Five-Axis Machining of Thin Curved Surface With Barrel-Taper-Ball Milling Cutter

Abstract

Abstract The use of blisk is essential for improving the performance of aviation engines, and the cutting of blade curved surface is the core of the blisk CNC machining. In response to the problem of traditional ball end milling cutter and barrel milling cutter that is difficult to take into account the quality and efficiency of curved blade machining, this article proposes a barrel-taper-ball milling cutter. The contour of the new cutter's barrel taper area is more fit with the blade curved surface, which is conducive to obtaining a larger cutting step and a tiny scallop height. Further, for the problem of weak-rigidity thin-wall curved surface machining chatter, the cutting dynamics model of the five-axis machining of the barrel-taper-ball milling cutter is established. Through the determination of the material contact criterion of the cutting edge micro element, the cutting geometry analysis algorithm of the five-axis processing of the blade curved surface is proposed. By deducing the forces in oblique cutting of the barrel taper area and the ball end area, the time-varying characteristics of the blade modes are explored, and the multiple frequently method theory is extended to the five-axis machining of the blade curved surface with barrel-taper-ball milling cutter. Finally, the stable state cutting parameter domain is constructed. Experiments and simulation indicate that the cutting step of the new cutter under the same surface roughness can increase by 7 times, the error of the cutting geometry solution of the blade curved surface is only 0.5%, the average error of the predicted three-dimensional cutting force is about 4.95%, and the optimized stable state cutting parameter can achieve machining without cutting chatter.