五軸側銑直紋曲面之切削力分析

Cutting Forces Analysis for Five-Axis Flank Milling of Ruled Surface

林忠誠(Zhong-Cheng Lin)

指導教授 ： 蔡哲雄

國立臺北科技大學/機電學院/製造科技研究所/碩士(2007年)

https://doi.org/10.6841/NTUT.2007.00316

摘要

端銑刀是銑床切削最重要的刀具之一，而端銑刀側銑之切削力大小及力量位置的變化則是影響側銑面的尺寸精度及表面粗度的主要關鍵。在今日要求高加工品質及高效率的切削製程規劃之下，有關端銑刀切削力的研究探討至為重要。
五軸加工機除了三個線性軸外，還有兩個旋轉軸，可以五軸同動，使用端銑刀直接來側銑直紋曲面(ruled surface)，包括斜面、歪斜面、圓錐面以及扭曲的葉輪葉片面等，相當方便而廣用，但在這一方面的側銑力分析則少有文獻報告，尤其是關於不可展的(indevelopable)直紋曲面側銑切削力分析，更是少見。本文提出一套端銑刀以五軸同動側銑直紋曲面的切削力分析，在方法上，首先以ㄧ般三軸側銑之切削力實驗來推估側銑之比切削力參數(specific cutting force parameters)，然後由五軸側銑模擬之刀具路徑資料(包括刀端座標及刀軸方向資料)，來計算刀具沿刀軸方向的實際進給率變化，進而算出瞬間的切削合力。因此，刀側貼著直紋曲面移動的切削力變化，可以模擬預測。本文方法適用於直紋曲面在預留均勻的餘料下，進行五軸側銑切削力預測，可有效提供五軸側銑切削的切削條件規劃。

關鍵字

五軸側銑切削 ； 切削力 ； 直紋曲面 ； 刀具路徑資料

並列摘要

The end mill cutter is one of the most important cutters of milling machines, and the magnitude of cutting forces and varies of forces position are main keys that influence dimensional precision and surface roughness of the machined surface. Today, where everyone requests high machining quality and efficiency for the planning of the cutting process, it is very important for us to probe into the research of cutting forces of the end mill cutter.
Five-axis machines include not only three linear axes but also two rotation axes that can to drive simultaneously the end mill cutter performing flank milling for the ruled surface. It is convenient and widely used. However, there are few reports containing the analysis of the cutting forces for flank milling, even rarer about the analysis of cutting forces for flank milling indevelopable ruled surface. This paper aims to show the analysis of cutting forces when flank milling ruled surface with end mill cutter for five-axis machining. First of all, the specific cutting force parameters are obtained by using three-axis end milling experiments. Second, use the five-axis flank milling tool path data to calculate the variation of feedrate along the axis direction of the end mill in order to compute the instantaneous tool cutting forces. Therefore, we can predict the variation of the cutting forces during the end mill moving along the ruled surface. The approach of this paper is suitable for carrying out prediction of cutting forces for flank milling ruled surface under reserving uniform material to cut by using five-axis machine. And it can effectively provide the suggestions of process planning for five-axis flank milling operation.

並列關鍵字

Five-axis flank milling ； Cutting forces ； Ruled surface ； Tool path data

參考文獻

[1] W.A. Kline, R. E. DeVor and I. A. Snareef, 〝The Prediction of Surface Accuracy in End Milling,〞 Journal of Engineering for Industry, Vol. 104, 1982, pp. 272-278.

[2] K. Suresh and D. C. H. Yang,〝Constant Scallop-height Machining of Free-form surfaces,〞 Journal of Engineering for Industry, Vol. 116, 1994, pp.253-259.

[4] J. J. Wang, S. Y. Liang and W. J. Book,〝Convolution Analysis of Milling Force Pulsation,〞ASME Journal of Engineering for Industry, Vol. 116, 1994, pp.17-25.

[5] W. A. Kline, R. E. DeVor and J. R. Lindberg,〝The Prediction of Cutting Forces in End Milling with Application to Cornering Cuts,〞 International Journal of Machine Tool Design and Research, Vol. 22, 1982, pp. 7-22.

[6] W. A. Kline and R. E. DeVor,〝The Effect of Runout on Cutting Geometry and Force in End Milling,〞 International Journal of Machine Tool Design and Research, Vol. 23, No. 2/3, 1983, pp. 123-140.