Features of processes of high-speed milling with a complex profile tool in the processing of aluminum alloys and composite materials

Features of processes of high-speed milling with a complex profile tool in the processing of aluminum alloys and composite materials

Автор: M.S. Vakulin, Yu.I. Gordeev, V.B. Yasinsky, A.S. Binchurov, P.V. Timoshev

Журнал: Siberian Aerospace Journal @vestnik-sibsau-en

Рубрика: Technological processes and material science

Статья в выпуске: 3 vol.24, 2023 года.

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Complex computational and experimental studies substantiate rational modes of milling of complex contour equiaxed surfaces with high accuracy of shape, dimensions and roughness parameters. Bars made of nanostructured carbide composite (produced by extrusion of WC-Co-Al2O3 bimodal powder mixtures) with increased strength, crack resistance and heat resistance were used as a workpiece material for the manufacture of new original tool designs. The combination of these properties is a necessary prerequisite for the effective operation of the developed designs of multi-blade cutters at high cutting speeds and under conditions of variable cyclic loads. A more complex kinematics of the joint rotational movement of the tool during milling dictates the need for new approaches when assigning rational cutting modes. To obtain reliable calculation formulae, numerical experiments were previously carried out, including simulation of the machining process using the VisualStudio integrated development environment, which supports Windows- Forms technology. The ability to display graphical 3D objects was implemented using an additional software product in the form of the Open CASCADE geometric core. Numerical experiments using MathCAD software products and based on the analytical provisions proposed in the work made it possible to evaluate the influence of cutting conditions, geometric parameters of the cutting part of the tool (profile and number of teeth), kinematics of relative movement in the “tool – part” system on the shape of surfaces and contour parameters (roughness) obtained during milling. A technique, algorithm and program for the automated calculation of cutting conditions have been developed, which have been verified during full-scale experiments and the manufacture of complex profile parts from aluminum alloys for drives of aerospace products (in the form of an equiaxial profile and parts of a pinion transmission of guidance mechanisms). At the same time, on the basis of a 3D model of products, control programs for CNC machines were created using MasterCAM. The practical significance and technical and economic efficiency of the proposed design and technological solutions is to increase productivity and reduce the complexity of processing (in comparison with the basic options) through the use of new multi-edge carbide tools for high-speed milling (including when processing composite materials).

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Milling, hard metal tools, mathematical modeling, complex surfaces, aluminum and titanium alloys, composites, processing quality

Короткий адрес: https://sciup.org/148329701

IDR: 148329701   |   DOI: 10.31772/2712-8970-2023-24-3-570-588

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