Dissertation > Industrial Technology > Metallurgy and Metal Craft > Metal cutting and machine tools > Milling and milling machine

Studying for Cutting Performance of Supper-Hard Milling Cutter Based on Multi-Scale Effect

Author LiKai
Tutor BaiQingShun
School Harbin Institute of Technology
Course Mechanical Manufacturing and Automation
Keywords polycrystalline diamond micro milling cutter scale effect finite element analysis wear characteristic surface roughness
Type Master's thesis
Year 2011
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With miro miniaturization being the core impetus of modern aviation and military affairs, micro-milling is recognized the most fit for machining micro parts, because of its unique advantages suitable for various materials of high precision processing in mesoscopic scales. Due to the decrease of the cutter and its cutting parameters, micro-milling has to face the special phenomenon caused by various scale effects, which is different from conventional cutting. Therefore, research on the wear mechanism of the cutter and the processing quality of the workpiece in scale effect, is important to promote the development of micro-milling technology and the equipment miniaturized in the national defense and civil field practicably. The research content of the subject includes the following three aspects:Firstly, the structure of the polycrystalline diamond micro milling cutter is designed, meanwhile the corresponding micro-milling finite element analysis also is completed. Through the calculation of the minimum thickness of cutting, the influence of micro-milling arose from the cutting edges obtuse radius and minimum cutting thickness in scale effect is analysed. Under the action of the scale effect, the unit cutting force of the micro-milling cutter increases nonlinearly with the decrease of the cutting depth. And the numerical simulation of the micro-milling cutter wear reaches the influence law of the cutting parameters to the cutter wear.Secondly, alclad is machined in micro-milling experiment. Wear morphology and damaged form of the polycrystalline diamond micro cutter is researched in micro-milling process with the SEM and EDS. According to it, five kinds of micro cutter wear characteristic is analysed.Finally, by detecting the surface roughness of the workpiece, the influence of the milling way to the surface quality is researched, and meanwhile the influence law of the cutting parameters to the roughness is analysed by the orthogonal experiment design. The experimental data is dealt with in regression analysis, and the numerical experience formula of the surface roughness is obtained, then getting a significant test.

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