Abstract

The nominal cutting contour for the thin wall deviates in response to the cutting forces during the end milling process. Elimination of mass in the milling process links to loss of stiffness, which favors the wall to deflect and promote error. This article proposes a novel way of generating rigidity during the process of milling. The tool paths were drafted to mill away mass in the central region and make corrugations at the edges simultaneously. This approach mitigated the thin wall deformation. Comparison experiments were conducted to analyze between open wall conventional type (OWC) and end corrugated pillar type (ECP). Force polygons were constructed to evaluate the effectiveness of machining. The experiments resulted in 36% more effectiveness in up milling and with 93% in down milling. An increase in the cutting effectiveness exhibited error-free and minimized cutting point deviation at the top of the wall. Eventually, the error diminished as the tool traversed to the bottom edge of the wall.

摘要

薄壁的标称切削轮廓会随着端铣削过程中的切削力而发生偏差。铣削过程中质量的消除与刚度损失有关，这有利于壁偏转并促进误差。本文提出了一种在铣削过程中产生刚度的新方法。刀具路径被设计成磨掉中心区域的质量并同时在边缘处产生波纹。这种方法减轻了薄壁变形。对开墙常规型（OWC）和端部波纹柱型（ECP）进行对比实验分析。构建力多边形以评估加工的有效性。实验结果表明，逆铣的效率提高了 36%，顺铣的效率提高了 93%。切割效率的提高表现出无差错，并最大限度地减少了壁顶部的切割点偏差。最终，随着工具移动到墙的底部边缘，误差逐渐减小。