An Innovative Process Design Model for Machined Surface Error Distribution Consistency in High-Efficiency Milling

Abstract

In the process of high-efficiency milling, due to the impact of plunge caused by the intermittent cutting of the milling cutter, there is a high frequency and small vibration between the milling cutter and the workpiece. In this paper, we construct a transient cutting model for high-efficiency milling tools under the action of vibration, and analyze the factors influencing the consistency of the machined surface error and its distribution. The design variables for the consistency of error distribution of high-efficiency milling are obtained, the significance analysis of the influencing factors is carried out using the central composite experimental design and the response surface method, the interaction between the influencing factors is studied, the evaluation index of the consistency of error distribution of milling is proposed, and the process design method for the consistency of error distribution of the machined surface is proposed and validated. The results of the verification experiments show that, compared with the original process scheme, the two maximum errors corresponding to the new process scheme are on average 61.3% smaller than those of the old process scheme, and the consistency of the machined surface error distribution of the new process scheme is significantly improved compared with the old process scheme.