Optimal Insert Edge Geometry for Minimum Specific Cutting Energy in Face Milling

最小比切削能之面銑刀片刃口幾何最佳化設計

李若寧(Ruo-Ning Lee) ； 賈其雅(Shaik Jakeer Hussain) ； 王俊志(Jiunn-Jyh Wang) ； 孟嘉祥(Chia-Hsiang Menq)

《中國機械工程學刊》 41卷6期 (2020/12) Pp. 725-733

摘要

This paper investigates the effect of the negative insert geometry on the specific cutting energy and explores the parametric space for optimal design to yield minimum specific energy in face milling. Double-sided negative cutting inserts offer many advantages over traditional face milling cutters, including a greater edge strength, improved stability, a higher feed rate, and a better economy. Accordingly, the present study employs the Taguchi robust design methodology to analyze the relative contribution of each geometry parameter of the cutting edge to the specific cutting energy in a face milling process through finite element simulation. A hybrid method consisting of the response surface methodology with a 2nd-order regression model and a genetic algorithm is then used to determine the optimal values of the insert edge geometry. The simulation results show that the specific cutting energy reduces with a larger rake angle of the cutting edge and a greater primary land width, as well as with a higher feed rate. The validity of the simulation results and analysis is confirmed by means of experimental milling trials using inserts fabricated with the optimal edge geometry.

關鍵字

face milling ； edge geometry ； cutting coefficient ； Taguchi method ； response surface methodology ； genetic algorithm

並列摘要

本論文針對面銑加工用雙面負角銑刀片，探討最佳刃口幾何設計以求得最小比切削能。先使用有限元素分析軟體模擬面銑加工，利用田口方法探討刃口幾何對比切削係數的影響。並運用反應曲面法及實驗設計，建立以進給、軸向切深與刃口幾何參數對切削係數的二階迴歸模型，再以基因演算法求取特定切削條件下的理想幾何參數，最後進行模擬與實際切削的差異比較，並驗證田口方法所分析的趨勢與迴歸模型之可靠度。模擬分析與驗證實驗的結果顯示，進給量對比切削係數有顯著的影響，進給量愈大比切削係數愈小。而在刃口幾何設計參數中，選擇較大的刃寬有助於比切削係數的減少，前傾角對比切削係數的貢獻度較大，角度增加也有助於比切削係數之減小，但有一範圍限制。最後以實驗證實最佳刀片刃口幾何設計之正確性。