PCD 微细铣磨刀具切削力建模与加工性能研究

A PCD micro milling-grinding combined machining tool structure with 0° side edge rake angle is proposed. The simulation model of single-edge and single-abrasive orthogonal cutting is constructed, and the mechanism of milling-grinding combined machining is analyzed. A cutting force model considering cutting edge shear force and tool flank face grinding force is constructed based on the micro-element method. According to the relationship between cutting tool structure and cutting parameters under up-milling and down-milling, the expression of cutting angle and the contact between cutting edge and workpiece are determined. On this basis, the prediction of the instantaneous cutting force of the mill is realized by fitting the shear force coefficient and grinding force coefficient through experiments, and cutting force model verification experiments are carried out on titanium alloy TC4. The experimental results show that the established cutting force model can effectively predict the cutting force in milling-grinding combined machining. The milling-grinding combined machining tool performance tests are further carried out on cemented carbide workpiece. The results show that compared with conventional PCD micro end mill, the developed PCD milling-grinding combined machining tool can effectively improve machining quality.