Titanium alloy is widely used for manufacturing structural parts of high-end equipment due to its excellent mechanical properties, despite difficulty in being machined. Nowadays, titanium alloy parts are mostly machined by ball-end milling cutters (BEMC), but the cutting edge structure of the BEMC limits the improvement in machining efficiency and surface quality of the parts. In this paper, a circular-arc milling cutter (CAMC) with large-curvature cutting edge was proposed; the differential geometry method was used for establishing the geometric model for the contour surface of the CAMC and the mathematical model for the spiral cutting edge line; the conversion matrix between grinding wheel and workpiece coordinates was introduced to derive the equation of grinding wheel trajectory when the rake face of the CAMC was ground; the self-designed CAMC was ground and tested in accuracy. The comparative research was conducted experimentally on the side milling of titanium alloy TC4 with the CAMC and BEMC, and consequently the variation laws of milling forces, wear morphology, and machined surface quality were obtained about the two types of milling cutters. The results indicated that the CAMC can effectively reduce the main milling force and keep the milling process stable. Moreover, the CAMC was worn slower and produced better surface quality than the BEMC.

钛合金虽然难以加工，但由于其优异的机械性能，被广泛用于制造高端设备的结构件。目前钛合金零件大多采用球头铣刀（BEMC）加工，但BEMC的切削刃结构限制了零件加工效率和表面质量的提高。本文提出了一种大曲率切削刃的圆弧铣刀（CAMC）；采用微分几何方法建立了CAMC轮廓面的几何模型和螺旋切削刃线的数学模型；引入砂轮与工件坐标的转换矩阵，推导出CAMC前刀面磨削时的砂轮轨迹方程；自行设计的CAMC经过研磨和精度测试。对钛合金TC4与CAMC和BEMC进行侧铣对比研究，得到了两种铣刀的铣削力、磨损形貌和加工表面质量的变化规律。结果表明，CAMC能有效降低主铣削力，保持铣削过程稳定。此外，与 BEMC 相比，CAMC 磨损得更慢并产生更好的表面质量。结果表明，CAMC能有效降低主铣削力，保持铣削过程稳定。此外，与 BEMC 相比，CAMC 磨损得更慢并产生更好的表面质量。结果表明，CAMC能有效降低主铣削力，保持铣削过程稳定。此外，与 BEMC 相比，CAMC 磨损得更慢并产生更好的表面质量。