Rapid calibration and verification of face milling force coefficient based onsemi-analytical method
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摘要: 铣削加工在航空航天和汽车制造领域应用十分广泛，预测铣削力是提高零件加工质量和效率的重要方式，而铣削力系数的高精度标定是预测铣削力的关键。铣削过程受多种因素的影响，传统铣削力系数标定方法基于刀具-工件之间的理论关系，却忽略了实际加工中其他因素对铣削力系数的影响。文章基于铣削力模型，推导出面铣削力系数的半解析计算模型，通过铣削加工实验获得切向力、径向力和进给力。考虑切削力峰值对刀具和工件振动的影响，引入修正因子对局部切削力系数进行修正。最后，基于标定的系数预测铣削力并进行了实验验证，铣削力理论预测值和实验值的最大相对误差为11.4%，预测值和实验值接近且相对误差较小。因此，文章提出的方法可以较好地标定面铣削力系数。Abstract: Milling is widely used in the fields of aerospace and automotive manufacturing. Predicting milling forces is an important way to improve the quality and efficiency of part processing, and high-precision calibration of milling force coefficients is the key to predicting milling forces. The milling process is influenced by various factors. Traditional milling force coefficient calibration methods are based on the theoretical relationship between tool and workpiece, but ignore the influence of other factors on the milling force coefficient in actual machining. Based on the milling force model, the semi analytical calculation model of face milling force coefficient is derived. The tangential force, radial force and feed force are obtained through milling experiments. Considering the impact of peak cutting force on tool and workpiece vibration, a correction factor is introduced to correct the local cutting force coefficient. Finally, based on the calibrated coefficients, the milling force was predicted and experimentally validated. The maximum relative error between the theoretical prediction and experimental values of the milling force was 11.4%, and the predicted and experimental values were close with relatively small relative errors. Therefore, the method proposed in this article can effectively calibrate the surface milling force coefficient.
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Key words:
- semi-analytical method /
- milling force coefficient /
- calibration /
- correction
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表 3 切削参数
实验
编号铣削
方式轴向切深/
mm径向切深/
mm每齿进给量/
（mm/f）主轴转速/
（r/min）1 逆铣 1 10 0.1 2 500 2 逆铣 1.5 10 0.15 2 500 3 逆铣 2 10 0.2 2 500 4 逆铣 2.5 10 0.25 2 500 
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表 4 铣削力系数
刀具 ${{{K}}_t}$ /（N/mm2） ${{{K}}_{{f}}}$ /（N/mm2） ${{{K}}_{{r}}}$ /（N/mm2） #1 1 560 658 58 #2 1 590 671 45
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表 5 铣削力预测值和实验值的误差
编号 ${F_{{x}}}$/N ${F_{{y}}}$/N ${F_{{\textit{z}}}}$/N 计算值 实验值 相对误差/（%） 计算值 实验值 相对误差/（%） 计算值 实验值 相对误差/（%） #1 683.2 760.4 10.1 485.3 547.9 11.4 25.4 28.0 9.2 #2 1 025.3 1 133.0 9.5 823.4 902.4 8.7 38.6 42.6 9.4
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