CN119703189A - Method for machining narrow groove with large depth-to-width ratio - Google Patents
Method for machining narrow groove with large depth-to-width ratio Download PDFInfo
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- CN119703189A CN119703189A CN202411691043.9A CN202411691043A CN119703189A CN 119703189 A CN119703189 A CN 119703189A CN 202411691043 A CN202411691043 A CN 202411691043A CN 119703189 A CN119703189 A CN 119703189A
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Abstract
本发明实施例提供了一种大夹套的大深宽比窄槽加工方法，使用普通三轴数控铣，通过基本数控程序控制刀具微量进给，铣刀瞬间受力后就立即回撤卸荷卸力进行缓冲，很好的改善了铣刀径向持续受力状况；随后立即通过侧铣方式进行圆弧插补，根据需要将窄槽扩宽进行精铣，能够最大限度地减小刀具与加工面的接触弧长，减小摩擦力；通过反复执行此循环步骤直至深窄槽加工完成。加工过程中，刀具径向受力小，持续受力时间短，刃口磨损均匀分布，刀具散热条件良好，可以有效避免刀具断裂，延长了刀具寿命。铣刀加工深度可达径长比7倍左右，大幅减少走刀次数，能够提高加工效率2‑3倍。
The embodiment of the present invention provides a method for processing narrow grooves with a large depth-to-width ratio in a large jacket. The method uses an ordinary three-axis CNC milling machine and controls the micro-feeding of the tool through a basic CNC program. After the milling cutter is subjected to force instantaneously, it immediately withdraws to relieve the load and perform buffering, which greatly improves the radial continuous force condition of the milling cutter. Then, circular arc interpolation is immediately performed through side milling, and the narrow groove is widened and fine milled as needed, which can minimize the contact arc length between the tool and the processing surface and reduce friction. This cycle step is repeatedly executed until the deep narrow groove processing is completed. During the processing, the tool is subjected to small radial force, the continuous force time is short, the edge wear is evenly distributed, and the heat dissipation condition of the tool is good, which can effectively avoid tool breakage and extend the tool life. The milling cutter processing depth can reach about 7 times the diameter-to-length ratio, which greatly reduces the number of passes and can improve the processing efficiency by 2‑3 times.
Description
Technical Field
The application relates to the technical field of numerical control machining, in particular to a method for machining a narrow groove with a large depth-to-width ratio.
Background
In the machine-building domain, high aspect ratio slot milling has been a very challenging task. This type of slot is commonly found in the aerospace, marine and precision machinery industries, such as machining of large jacketed slot (see fig. 3), aircraft tab structures, motor rotor slots, and the like, where such deep slots generally require smaller slot sizes, greater depths, and better surface quality. The performance of these parts is directly related to the stability and reliability of the whole system, so the requirements on processing precision and quality are high.
The traditional milling method includes full-edge full-groove milling, limited time insert milling and re-expansion milling, a high-rotation-speed high-feeding dynamic milling mode of a light turning and fast running type, deep narrow groove processing by customizing a special disc milling cutter and the like, the problems of edge collapse, cutter breakage, low efficiency, poor surface quality and the like are frequently faced when the narrow groove with the large depth-to-width ratio is milled, meanwhile, the heat dissipation condition of a processing area is poor, free cutting heat accumulation is realized, the cutter wear is fast, the service life is short, the cutter cost is high, the thermal damage of a workpiece is easily caused, the processing quality is influenced, and the precision requirement of narrow groove processing is difficult to realize.
Disclosure of Invention
In order to solve the problems, the embodiment of the invention provides a processing method of a thin narrow groove for a large jacket.
The embodiment of the invention provides a processing method of a narrow groove with a large depth-to-width ratio, which comprises the following steps:
Step S1, machining a cutter falling hole by using a drill bit at the initial position of a groove to be machined, and enabling the cutter falling hole to be deep to the bottom of the groove;
s2, after the milling cutter is replaced, cutting at a pre-drilled cutter falling hole to the bottom of the processing groove;
Step S3, feeding the milling cutter by T+0.05mm along the narrow groove machining direction, wherein T is the width of a cutter groove gap, and the calculation formula is T= (groove width-milling cutter diameter)/(2), and retracting the milling cutter in the reverse direction immediately by Tmm;
S4, performing circular arc interpolation by taking the retracted coordinate point as a circle center, laterally milling a semicircle with the radius of R=Tmm, returning to the circle center immediately, reaching the starting point position of the next processing cycle, performing widening finish milling on the narrow groove, processing the whole narrow groove to the required size, and leveling to the transverse feeding position of the previous step;
and S5, repeating the step S3 and the step S4, stopping processing when the processing length of the narrow groove reaches the designated processing length, and finishing the processing of the narrow groove with the large depth-to-width ratio.
In some embodiments, the method further comprises selecting drill bit, mill size, cutter material, and machining cutting parameters that match the machining requirements.
In some embodiments, the determining tool material includes selecting a cemented carbide end mill for a steel type product.
In some embodiments, the selecting drill bit, milling cutter dimensions that match machining requirements includes pre-drilling a drill bit diameter selected to be equal to the width value of the slot to be machined for milling a down cutter.
In some embodiments, the selecting of drill bit, mill size that matches machining requirements further includes selecting an end mill diameter that is 0.5mm smaller than the machining slot size and a mill diameter that is 0.5mm smaller than the drill bit diameter.
In some embodiments, the step S1 further comprises omitting the step S1 if the start position port of the processed groove is open.
In some embodiments, the step S2 further comprises the step of enabling full-edge milling to be achieved by enabling the maximum machining depth of the milling cutter to be the length of the whole cutting edge of the cutter, so that the abrasion distribution of the cutting edge of the cutter is uniform.
The embodiment of the invention provides a large-aspect-ratio narrow-groove machining tool which is used for executing the large-aspect-ratio narrow-groove machining method in any embodiment.
According to the processing method of the narrow groove with the large depth-to-width ratio, the unloading force buffer is immediately withdrawn after the milling cutter is fed transversely in a micro-quantity mode, and the problem existing in the traditional processing method is effectively solved by combining the side processing mode. The method specifically reduces the stress of the cutter by adopting side milling, reduces the abrasion and fracture risk of the milling cutter and prolongs the service life of the cutter through unloading buffering during processing, and simultaneously reduces vibration of the cutter and thermal damage of a workpiece and improves the processing quality of the narrow groove by reducing accumulated cutting heat. In addition, the method can also improve the processing efficiency, shorten the production period and reduce the production cost.
Drawings
The drawings illustrate generally, by way of example and not by way of limitation, various embodiments discussed herein.
FIG. 1 is a schematic diagram of the effect of processing details;
FIG. 2 is a schematic diagram of a processing step;
FIG. 3 is a schematic diagram of the structure of a large jacketed tank.
Detailed Description
For a more complete understanding of the nature and the technical content of the embodiments of the present application, reference should be made to the following detailed description of embodiments of the application, taken in conjunction with the accompanying drawings, which are meant to be illustrative only and not limiting of the embodiments of the application.
In describing embodiments of the present application, unless otherwise indicated and limited thereto, the term "connected" should be construed broadly, for example, it may be an electrical connection, or may be a communication between two elements, or may be a direct connection, or may be an indirect connection via an intermediate medium, and it will be understood by those skilled in the art that the specific meaning of the term may be interpreted according to circumstances.
It should be noted that, the term "first\second\third" related to the embodiment of the present application is merely to distinguish similar objects, and does not represent a specific order for the objects, it is to be understood that "first\second\third" may interchange a specific order or sequence where allowed. It is to be understood that the "first\second\third" distinguishing objects may be interchanged where appropriate such that embodiments of the application described herein may be practiced in sequences other than those illustrated or described herein.
Selecting a cutter:
Taking a common triaxial numerical control milling as an example, selecting drill bit and milling cutter sizes matched with machining requirements according to part materials and length, width and depth sizes of a groove to be machined, determining cutter materials and machining cutting parameters, selecting a hard alloy end mill for steel products, selecting a pre-drilling cutter-falling drill bit diameter to be equal to the width value of the groove to be machined so as to facilitate milling, selecting an end mill diameter which is generally about 0.5mm smaller than the machining groove size, and reducing the cutter diameter by 0.5mm smaller than the drill bit diameter
The embodiment of the invention provides a processing method of a narrow groove with a large depth-to-width ratio, which is shown in fig. 2, and comprises the following steps S1 to S5.
And S1, machining a cutter falling hole by using a drill bit at the initial position of the groove to be machined, and enabling the cutter falling hole to be deep to the bottom of the groove. The starting position port of the processed groove is opened, and the step can be omitted.
And S2, after the milling cutter is replaced, cutting the cutter to the bottom of the machining groove at the position of the pre-drilling cutter falling hole, wherein the maximum machining depth of the milling cutter can reach the length value of the whole cutting edge of the cutter, so that full-edge milling is truly realized, and the abrasion distribution of the cutting edge of the cutter is uniform.
Step S3, then the milling cutter is fed by T+0.05mm along the machining direction of the narrow groove, the center point of the cutter track reaches the point 1, the milling cutter is retracted by Tmm to the point 2 in the reverse direction immediately, the milling cutter is retracted by the step 2 in the figure 2, the actual machining amount of the milling cutter is only a trace of 0.05mm after the milling cutter is completed in the step 2, the dimension marked by the step 1 in the figure 2 is adopted, that is, the milling cutter is retracted and unloaded after being transversely fed by 0.05mm, and the problems of cutter tipping, breakage and the like caused by continuous increase of the radial stress of the cutter can be effectively avoided.
T= (flute width-milling cutter diameter)/(2) -can also be referred to as knife slot gap width
And S4, performing circular arc interpolation by taking the retracted coordinate point as a circle center, referring to step 3 in the figure 2, laterally milling a semicircle with the radius of R=Tmm, and then returning to the circle center, referring to step 4 in the figure 2, to reach the starting point position of the next processing cycle. The step mainly comprises the steps of widening and finish milling a narrow groove, wherein a processed area is an arc interpolation area, see step 3 in the figure 2, processing the whole narrow groove to a required size, and leveling the narrow groove to a transverse feeding position of the previous step;
and S5, repeating the steps S3-S4, stopping processing when the processing length of the narrow groove reaches the designated processing length, and finishing the processing of the narrow groove with the large depth-to-width ratio. This milling process is visually referred to as "pecking milling".
In the embodiment of the invention, for instantaneous unloading after micro-feeding:
In the transverse cutting process of machining, a micro-feeding strategy is adopted, namely when the cutter finishes a given micro-quantity, feeding is stopped immediately, immediate withdrawal is performed, load unloading is performed, and accordingly continuous increase of radial stress of the milling cutter is avoided, and the problems of tipping, cutter breakage and machining heat accumulation are effectively avoided.
In the embodiment of the invention, for side milling operation:
and after unloading, carrying out milling finish machining on the narrow groove by matching with a side milling mode. The side milling mode can effectively reduce the contact area between the cutter and the processing surface of the workpiece so as to reduce friction force, reduce the generation of cutting heat and be more beneficial to the diffusion of the cutting heat.
Compared with the traditional cold working scheme of narrow grooves, in the traditional groove milling mode, the whole normal arc surface of the milling cutter has the contact arc length of the cutter, reaches the maximum value which is approximately 1/2 of the circumference of the cutter, so that the friction force, the radial cutting force and the like reach the maximum value, and the cutter is continuously stressed all the time. In the machining process, the axial machining depth of the cutter is greatly limited, the narrow groove cannot be machined once when the depth of the narrow groove is slightly larger, so that the longitudinal feeding frequency is required to be increased, the machining time is longer, the machining efficiency is low, meanwhile, the vibration of the cutter is aggravated, the heat dissipation condition is poorer, and the machining quality of the narrow groove is poorer.
The transverse micro-feeding of the milling cutter is followed by immediate withdrawal of unloading force and circular interpolation side milling, which utilizes the characteristics of instant stress, immediate unloading and difficult damage to the cutter, and simultaneously, the side milling reduces the radial cutting-tool feeding amount of the cutter, greatly reduces the contact arc length of the cutter and the workpiece, and reduces the friction force of the cutter. The cutter has small comprehensive stress during processing, can unload and buffer, can adopt large axial cutting depth to realize cutting of the full cutting edge of the milling cutter, always controls the cutting force at a lower level, can avoid damaging the cutting cutter, can ensure the cutter to wear and distribute evenly, effectively improves the heat dissipation condition, dissipates heat quickly, prolongs the service life of the cutter,
One application of the above-described embodiment of the present application is as follows. Let us assume that we are working a jacket with a high aspect ratio narrow slot with dimensions of 40mm depth and 6.5mm width. Selecting a cutter:
Taking a common triaxial numerical control milling as an example, selecting a phi 6.5mm common high-speed steel drill bit matched with the machining requirement according to the part material and the length, width and depth dimensions of a groove to be machined, as a pre-drilling cutter hole, selecting a phi 6mm lengthened end mill, and selecting an integral hard alloy milling cutter, wherein the rigidity is better, and the machining surface quality is higher;
At least comprises the following steps:
And S110, selecting a drill rotating speed S800r/min and a feeding speed F60mm/min at the starting position of the groove to be processed, and processing a cutter dropping hole with a drill with the depth more than or equal to 40mm. In this example, the slot start port is open, and this step can be omitted.
And step S120, selecting milling cutter cutting parameters, namely, rotating speed S1200r/min, feeding speed F100mm/min, and cutting at a pre-drilling cutter hole position to be slightly larger than the bottom 40mm of the groove after replacing the milling cutter.
Step S130, feeding t+0.05=0.3 mm in the slot machining direction, and immediately retracting 0.25mm in the opposite direction of feeding, wherein the actual machining amount of the milling cutter is only 0.05mm each time.
T= (6.5-6)/(2=0.25) -may also be referred to as knife slot gap width
And step S140, performing circular arc interpolation by taking the coordinate point position of the retracted milling cutter as the circle center, moving a semicircle with the radius of R=0.25 mm, and returning to the circle center, so that the processing groove is widened and refined in a side milling mode, the whole narrow groove is processed to the required size, and the transverse feeding position of the previous step is leveled.
And step S150, repeating the steps S130-S140, stopping processing when the processing length of the narrow groove reaches the designated processing length, and finishing the processing of the narrow groove with the large depth-to-width ratio. This milling process is visually referred to as "pecking milling".
The technical schemes described in the embodiments of the present application may be arbitrarily combined without any collision.
The foregoing is merely illustrative of the present application, and the present application is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
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