Turning process design method for machining surface residual height of large conical surface component

Abstract

The invention discloses a large conical surface component machining surface residual height turning process design method. The method comprises the following steps that S1, the maximum residual height of the lower end face and the upper end face of a turned conical surface component and the maximum residual height of the outer conical surface of the turned conical surface component are calculated; s2, analyzing the influence of the taper angle of the machining surface on the maximum residual height of the machining surface; s3, calculating the maximum residual height consistency of the upper and lower end faces and the outer conical surface; s4, calculating the influence of the arc radius of the cutter on the residual height of the machined surface and the critical value of each turn; according to the method, aiming at the efficient and high-quality machining requirements of the large titanium alloy conical surface component, the maximum residual height of the lower end face and the upper end face of the turned conical surface component and the maximum residual height of the outer conical surface of the turned conical surface component and key process control variables of the turned conical surface component are researched, and the large titanium alloy conical surface component turning process experiment is combined. And a machining surface maximum residual height calculation model is constructed, so that the machining surface residual height consistency and the machining surface quality of the turned large conical surface component are improved.

Description

Technical Field

[0001] The present invention relates to a turning process design method for the residual height of the machining surface of a large conical surface component. Specifically, it relates to a method for calculating the maximum residual height of the upper and lower end surfaces and the outer conical surface of the turning conical surface component, an analysis method for the influence of the cone angle of the machining surface on the maximum residual height of the machining surface, a method for calculating the consistency of the maximum residual height of the lower and upper end surfaces and the outer conical surface, a method for calculating the critical value of the feed per revolution, and a turning process design scheme for large conical surface components. Background Art

[0002] Large titanium alloy conical surface components have a diameter of 400mm to 900mm and a height of 240mm. As key parts of aviation transmission systems, the cutting surface of such components must first achieve precise shape control and meet extremely high geometric shape accuracy requirements to meet high fatigue life and high reliability service performance requirements. Turning is the main process method for machining large titanium alloy conical surface components. The maximum residual height of the turning surface of such components not only directly affects the cutting layer area, but also affects the surface roughness and surface shape accuracy of the components. It is an important indicator for controlling the machining accuracy of large titanium alloy conical surface components.

[0003] When turning the lower and upper end faces and outer conical surfaces of large conical components, the machined surfaces should meet the requirements of low maximum residual height and high consistency. The taper angle of the component machining surface, the tool tip angle, tool tip arc radius, tool main deflection angle, secondary deflection angle, feed direction, and feed per revolution are important factors affecting the maximum residual height of the machined surface. Improper selection of the above process parameters will not only cause cutting interference between the tool and the workpiece, but also directly affect the size and distribution consistency of the maximum residual height of the machined surface. The existing maximum residual height solution and process design method for turning large conical components only aims to control the maximum residual height of a single machined surface, ignoring the influence of the matching relationship between the taper angle of the machined surface and the secondary cutting edge, tool tip arc, and feed per revolution on the maximum residual height of the machined surface. It cannot meet the requirements of maximum residual height consistency of multiple machined surfaces of the component and the requirements of machined surface shape accuracy. It is necessary to study the turning process design method for residual height of large conical components.

[0004] Aiming at the demand for efficient and high-quality processing of large titanium alloy conical surface components, the present invention studies the maximum residual height of the lower and upper end faces and the outer conical surface of turning conical surface components and its key process control variables, proposes a method for solving the consistency of the maximum residual height of the upper and lower end faces and the outer conical surface and the critical value of the feed per revolution, combines the turning process experiment of large titanium alloy conical surface components, constructs a solution model for the maximum residual height of the machining surface, and proposes a turning process design scheme for large conical surface components, so as to improve the consistency of the residual height of the machining surface and the machining surface quality of turning large conical surface components. Summary of the invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a method for designing a residual height turning process for machining a large conical surface component.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A method for designing a turning process for a residual height of a machining surface of a large conical surface component comprises the following steps:

[0008] S1. First, calculate the maximum residual height of the lower and upper end faces and the outer conical surface of the turning conical surface component, the tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively:

[0009] κ s =270°-(α+κ r0 ), κ s ′=270°-(α+κ r0 +ε r ), (1)

[0010] In the formula, κ r0 is the initial cutting edge angle of the tool, κ s is the angle between the cutting edge s of the tool and the feed direction along the clockwise direction, κ s ' is the angle between the cutting edge s' of the tool and the feed direction along the clockwise direction, α is the taper angle of the machined surface, v fs is the feed speed along the cutting edge s direction of the tool, v fs ' is the feed speed along the cutting edge s' direction of the tool, ε r is the tip angle, v f ' is the feed speed in the interference zone between the tool and the workpiece determined by the tool cutting edges s and s';

[0011] Tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively:

[0012]

[0013] In the formula, ε r is the blade tip angle, κ r is the main deflection angle of the tool when working, κ r ' is the tool deflection angle, κ s ' is the angle between the cutting edge s' and the feed direction in the clockwise direction, κ s is the angle between the tool cutting edge s and the feed direction along the clockwise direction, and the feed direction in the interference zone between the tool and the workpiece is determined by s and s';

[0014] When the tool cuts the outer surface of the component, the maximum residual height h max for:

[0015]

[0016] Where α is the cone angle of the machined surface, κ r0 ' is the initial tool deflection angle, κ r0 is the initial cutting angle of the tool, ε r is the tool tip angle, f is the feed rate per revolution of the workpiece, h max is the residual height;

[0017] Among them, the value range of the machined surface cone angle α is:

[0018] 90°-κ r0 <α<270°-(κ r0 +ε r ), or -90°-κ r0 <α<90°-(κ r0 +ε r ) (12)

[0019] Where α is the cone angle of the machined surface, κ r0 ' is the initial main deflection angle of the tool, κ r0 is the initial cutting angle of the tool, ε r is the knife tip angle;

[0020] S2. According to the parameters calculated in step S1, the influence of the taper angle of the machined surface on the maximum residual height of the machined surface is analyzed. During the cutting process of the tool, the taper angle of the machined surface that interferes with the workpiece is:

[0021] 90°-(κ r0 +ε r )<α<90°-κ r0 (13)

[0022] Where α is the cone angle of the machined surface, κ r0 is the initial cutting angle of the tool, ε r is the tool tip angle. The initial main deflection angle and tool tip angle directly affect the size of the interference area between the tool and the workpiece. This formula can be used to determine whether cutting interference occurs when the selected tool cuts the outer surface of a component with different machining surface taper angles.

[0023] S3. According to the data parameters of the tool and large conical surface component processing calculated in step S1, the maximum residual height consistency of the upper and lower end faces and the outer conical surface is solved. The solution method for the consistency of the maximum residual height of the upper and lower end faces and the outer conical surface is:

[0024]

[0025] In the formula, i and j are the outer surfaces of components with different machined surface taper angles, Δh max is the maximum residual height difference between the outer surfaces of components i and j, h maxj (α j ,κ r0j ,ε rj ,f j ) is the minimum value of the maximum residual height on the outer surface of the component, δ hmax It is an evaluation index for the consistency of the maximum residual height distribution on the outer surface of a component, and can obtain the cutting process parameters that achieve the best consistency of the maximum residual height distribution on the outer surfaces of two components;

[0026] S4. When the tool tip radius is greater than 0 mm, the instantaneous cutting layer relationship of the outer surface of a large titanium alloy component is obtained by using the maximum residual height and tangent point s' formed by the intersection of two arc edges. r , get the critical value of feed rate f s'r for::

[0027]

[0028] In the formula, r ε is the tool tip radius, s r is the point of contact between the cutting edge s and the tool tip arc, s' r It is the point of tangency between the tool's secondary cutting edge s' and the tool tip arc;

[0029] When the feed rate is less than the critical value f s'r hour:

[0030] When the feed rate is greater than the critical value f s'r hour:

[0031]

[0032] In the formula, The feed rate is less than the critical value f s'r The maximum residual height of the machined surface is The feed rate is greater than the critical value f s'r The maximum residual height of the machined surface;

[0033] The initial cutting edge angle κ of the tool is used r0 are 95°, corresponding to the tool tip angle ε r When the tool radius is 80° and the tool tip radius is 0.4mm and 0mm, the maximum residual height calculation results of the outer surface of large conical components with a diameter of 400mm to 900mm are compared;

[0034] S5. Based on the analysis results of steps S1, S2, S3, and S4, a cutting parameter scheme with a tool tip arc radius of 0.4 mm is used to verify the outer surface of a large conical component with a diameter of 400 mm to 900 mm, and the maximum residual height of the machined surface is obtained. Based on the verification result, the maximum residual height of the machined surface is corrected:

[0035] h max =k α ×h max ' (18)

[0036] In the formula, h max ' is the maximum residual height of the machined surface after correction, k α is the correction factor;

[0037] Among them, when the cone angle of the machined surface is -90°, the correction coefficient k α is 1.663. When the taper angle of the machined surface is 33°, the correction coefficient k α is 2.451, and the maximum residual heights of the upper and lower end surfaces and the outer conical surface obtained, the error between the calculated results and the experimental results is less than 6%, and their distributions show similar characteristics.

[0038] Preferably, the formula (4) and the formula (5) in the step S1 are the influence of the initial main rake angle of the tool, the tool tip angle, and the taper angle of the machined surface on the maximum residual height. It is also found that when the same tool is used, the attitude angle between the tool and the workpiece axis is kept unchanged, and the same cutting parameters are used, the maximum residual heights of the outer surfaces of components with different taper angles of the machined surface are usually not equal.

[0039] Preferably, the formula (4) and formula (5) used in step S1 are used to obtain the maximum residual height h of the outer surface of the large titanium alloy component when two tools are turned. max Curve of feed rate f per revolution, where the initial main deflection angles κ of the two tools r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r The inner diameter of the component is 400mm to 900mm, and the cone angles of the lower and upper end faces and the outer conical surface of the component are -90° and 33° respectively.

[0040] Preferably, the formula (6) in step S2 is: the initial main deflection angle of the tool and the tool nose angle directly affect the size of the interference area between the tool and the workpiece. Formula (6) is used to determine whether cutting interference occurs when the selected tool cuts the outer surface of the component with different machining surface taper angles, and obtain the maximum residual height h of the outer surface of the large titanium alloy component when turning. max Curve of the machined surface taper angle α and tool cutting interference area, where the initial main deflection angles κ of the two tools r0They are 95° and 93° respectively, corresponding to the tool tip angle ε r The angles are 80° and 55° respectively, and the feed rate per revolution f is 0.1mm / r. Different tools are used to keep the attitude angle between the tool and the workpiece axis unchanged. At the same time, the same cutting parameters are used to turn the outer surface of the component. The interference area during tool processing is different

[0041] Preferably, the maximum residual height consistency relationship diagram of the upper and lower end faces and the outer conical surface of the large titanium alloy component is obtained by the equations (4) and (7) in step S2, wherein the initial main deflection angles κ of the two tools are r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, and the feed rate f per revolution is 0.08mm / r, 0.09mm / r and 0.10mm / r respectively.

[0042] Preferably, the formula (4) in step S1 can effectively reduce the maximum residual height difference Δh of the outer surfaces of the two components by changing the initial main deflection angle, the tool tip angle and the feed per revolution. max .

[0043] Preferably, the formula (4), formula (5) in step S1 and the formula (9), formula (10) in step S4 are used to calculate the initial main deflection angle κ of the tool: r0 are 95°, corresponding to the tool tip angle ε r The comparison results of the maximum residual height calculation results of the outer surface of large conical components with diameters of 400mm to 900mm are shown when the angle is 80° and the tool nose arc is 0.4mm and 0mm.

[0044] Preferably, the equations (9) and (10) in step S4 are used to calculate the maximum residual height of three surfaces with a tool tip arc radius of 0.4 mm, and the maximum residual height of the upper and lower end surfaces and the outer conical surface. The error between the calculated results and the experimental results is less than 6%.

[0045] Compared with the prior art, the technical effects and advantages of the present invention are as follows: the residual height turning process design method for the machining surface of a large conical component, the present invention constructs a maximum residual height consistency solution model for the machining surface based on the cone angle formed by the lower and upper end faces and the outer conical surface of the component and the axis of the workpiece, and its influence on the residual height of the machining surface, and utilizes the matching relationship between the machining surface cone angle and the tool tip angle, tool tip arc radius, tool main deflection angle, secondary deflection angle and feed direction, and feed per revolution to obtain a process design scheme for the consistency of residual height of the machining surface of a large conical component, which significantly reduces the error of the maximum residual height solution model for the machining surface and effectively improves the consistency of residual height of the machining surface of a large conical component. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a schematic diagram of the instantaneous cutting layer when turning the outer surface of a large titanium alloy component according to the present invention;

[0047] Figure 2 It is a partial schematic diagram of the instantaneous cutting layer of the outer surface of a large titanium alloy component turned in the present invention;

[0048] Figure 3 Schematic diagram of tool angle when (a) α = -90° for tool working angle of turning the outer surface of a large titanium alloy component according to the present invention;

[0049] Figure 4 It is a schematic diagram of the maximum residual height of the upper end surface and the outer conical surface during turning of the present invention;

[0050] Figure 5 It is a schematic diagram of the structure of the taper angle and the maximum residual height of the machining surface of the present invention;

[0051] Figure 6 Schematic diagram of the residual height of the upper and lower end faces and the outer conical surface of the component under different cutting conditions of the present invention;

[0052] Figure 7 It is a schematic diagram of the instantaneous cutting layer when turning the outer surface of a large titanium alloy component under the influence of the tool tip arc radius of the present invention;

[0053] Figure 8 It is a schematic diagram of the turning process design method of a large conical surface component of the present invention;

[0054] Fig. 9 A schematic diagram of a turning process design method for achieving high consistency of residual height on a machined surface according to the present invention;

[0055] Fig.10 The tool angle when (b) α = 0° is the tool working angle for turning the outer surface of a large titanium alloy component according to the present invention. DETAILED DESCRIPTION

[0056] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0057] Implementation Example 1

[0058] See also Figure 1-10 , a method for designing a turning process for a large conical surface component with a residual height, comprising the following steps:

[0059] S1. First, calculate the maximum residual height of the lower and upper end faces and the outer conical surface of the turning conical surface component. The outer surface structure, feed path and cutting layer parameters of large titanium alloy components are as follows: Figure 1 As shown in the figure, n is the spindle speed of the machine tool, f is the feed rate of the workpiece per revolution, v f is the feed speed, a p is the cutting depth, h D is the cutting thickness, b D is the cutting width, h max is the residual height, ε r is the blade tip angle, κ r0 is the initial cutting edge angle of the tool, κ r0 ' is the initial main deflection angle of the tool, κ r is the main deflection angle of the tool when working, κ r ' is the tool deflection angle.

[0060] in accordance with Figure 1 When the tool cuts the lower and upper end faces of a component with a surface taper angle α of -90° and the outer conical surface of a component with a surface taper angle α of 33°, the working angle is as follows: Figure 3 and Fig.10 As shown,

[0061] Depend on Figure 3 and Fig.10 , tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively:

[0062] κ s =270°-(α+κ r0 ), κ s ′=270°-(α+κ r0 +ε r ), (1)

[0063] In the formula, κ r0 is the initial cutting edge angle of the tool, κ s is the angle between the cutting edge s of the tool and the feed direction along the clockwise direction, κ s ' is the angle between the cutting edge s' of the tool and the feed direction along the clockwise direction, α is the taper angle of the machined surface, v fs is the feed speed along the cutting edge s direction of the tool, v fs ' is the feed speed along the cutting edge s' direction of the tool, ε r is the tip angle, v f ' is the feed speed in the interference zone between the tool and the workpiece determined by the tool cutting edges s and s';

[0064] Depend on Figure 3 , Fig.10And formula (1), we can get the tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively:

[0065]

[0066] In the formula, ε r is the blade tip angle, κ r is the main deflection angle of the tool when working, κ r ' is the tool deflection angle, κ s ' is the angle between the cutting edge s' and the feed direction in the clockwise direction, κ s is the angle between the tool cutting edge s and the feed direction along the clockwise direction, and the feed direction in the interference zone between the tool and the workpiece is determined by s and s';

[0067] Depend on Figure 1 , Figure 2 When the tool cuts the outer surface of the component, the maximum residual height h is max for:

[0068]

[0069] Where α is the cone angle of the machined surface, κ r0 ' is the initial tool deflection angle, κ r0 is the initial cutting angle of the tool, ε r is the tool tip angle, f is the feed rate per revolution of the workpiece, h max is the residual height;

[0070] Among them, the value range of the machined surface cone angle α is:

[0071] 90°-κ r0 <α<270°-(κ r0 +ε r ), or -90°-κ r0 <α<90°-(κ r0 +ε r ) (twenty one)

[0072] Where α is the cone angle of the machined surface, κ r0 ' is the initial main deflection angle of the tool, κ r0 is the initial cutting angle of the tool, ε r The tip angle of the knife.

[0073] According to equations (4) and (5), the initial main rake angle of the tool, the tool tip angle, and the machined surface taper angle affect the influence of the feed rate per revolution on the maximum residual height. At the same time, it is found that when the same tool is used, the attitude angle between the tool and the workpiece axis is kept unchanged, and the same cutting parameters are used, the maximum residual heights of the components with different machined surface taper angles are usually not equal.

[0074] Using equations (4) and (5), we can obtain the turning performance of two tools: Figure 1 The maximum residual height h of the outer surface of the large titanium alloy component shown max The curve of feed rate f per revolution is as follows: Figure 3 , Fig.10 As shown in Figure 2, the initial main deflection angles of the two tools are r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r The inner diameter of the component is 400mm to 900mm, and the cone angles of the machined surfaces of the lower and upper end faces and the outer conical surface of the component are -90° and 33° respectively.

[0075] Depend on Figure 4 , using the same tool and the same cutting parameters, keeping the attitude angle between the tool and the workpiece axis unchanged, the maximum residual heights of the outer conical surface and the lower and upper end surfaces of the turned component are not equal.

[0076] At the same time, it is found that when different tools are used to cut the outer surface with the same machined surface taper angle, the feed rate per revolution has a significantly different effect on the maximum residual height. Under the condition that the attitude angle between the tool and the workpiece axis remains unchanged, the difference between the maximum residual height of the outer conical surface and the lower and upper end surfaces of the component can be changed by changing the initial main deflection angle and tool tip angle of the tool.

[0077] Implementation Example 2: Analysis method of the influence of the taper angle of the machining surface on the maximum residual height of the machining surface.

[0078] S2. Based on the parameters calculated in step S1, the influence of the taper angle of the machined surface on the maximum residual height of the machined surface is analyzed. By formula (1), Figure 3 , Fig.10 During the cutting process, the cone angle of the machined surface that interferes with the workpiece is:

[0079] 90°-(κ r0 +ε r )<α<90°-κ r0 , (twenty two)

[0080] Where α is the cone angle of the machined surface, κ r0 is the initial cutting angle of the tool, ε ris the tool tip angle. According to formula (6), the initial main rake angle and tool tip angle of the tool directly affect the size of the interference area between the tool and the workpiece. This formula can be used to determine whether cutting interference occurs when the selected tool cuts the outer surface of a component with different machined surface taper angles.

[0081] Using formula (4) to (6), we can obtain the turning Figure 1 , Figure 2 The maximum residual height h of the outer surface of the large titanium alloy component shown max The curve of the machined surface taper angle α and the tool cutting interference area, such as Figure 6 As shown in Figure 2, the initial main deflection angles of the two tools are r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, and the feed rate per revolution f is 0.1mm / r.

[0082] From equation (4), equation (5) and Figure 5 , using different tools, keeping the attitude angle between the tool and the workpiece axis unchanged, and using the same cutting parameters at the same time, turning the outer surface of the component, the interference area of ​​the tool during machining is different.

[0083] Compare the machined surface taper angle (-90°-κ r0 , 90°-κ r0 -ε r ) and (90°-κ r0 , 270°-κ r0 -ε r ) area, keep the attitude angle between the tool and the workpiece axis unchanged, use the same cutting parameters and tool to turn the outer surface of the component, and the maximum residual height formed has the same characteristics as the change of the taper angle of the machined surface. When replacing tools with different initial main deflection angles and tool nose angles, the maximum residual height in the above two taper angle areas of the machined surface will change accordingly.

[0084] Implementation Example 3: Method for calculating the consistency of the maximum residual height of the upper and lower end faces and the outer conical surface.

[0085] S3. According to the data parameters of the tool and large conical surface component processing calculated in step S1, the maximum residual height consistency of the upper and lower end faces and the outer conical surface is solved. According to formula (4) and formula (5), the solution method for the maximum residual height consistency of the upper and lower end faces and the outer conical surface is:

[0086]

[0087] In the formula, i and j are the outer surfaces of components with different machined surface taper angles, Δh max is the maximum residual height difference between the outer surfaces of components i and j, h maxj (α j,κ r0j ,ε rj ,f j ) is the minimum value of the maximum residual height on the outer surface of the component, δ hmax It is an indicator for judging the consistency of the maximum residual height distribution on the outer surface of a component, and can obtain the cutting process parameters that achieve the best consistency of the maximum residual height distribution on the outer surfaces of two components.

[0088] Using equations (4) to (7), we can obtain the turning Figure 1 The maximum residual height consistency relationship diagram of the upper and lower end surfaces and the outer conical surface of the large titanium alloy component is shown in the figure. Figure 6 As shown in Figure 2, the initial main deflection angles of the two tools are r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, and the feed rate f per revolution is 0.08mm / r, 0.09mm / r and 0.10mm / r respectively.

[0089] From formula (4) and Figure 6 For the outer surfaces of two components with different machined surface taper angles, by changing the initial main deflection angle, tool tip angle and feed per revolution, the maximum residual height difference Δh of the outer surfaces of the two components can be effectively reduced. max .

[0090] By using the above method, the maximum residual height difference Δh of the outer surfaces of the two components can be obtained. max The cutting process parameter solution that achieves the minimum value.

[0091] Implementation Example 4: The influence of tool tip arc radius on the residual height of the machined surface and the calculation method of the critical value of feed per revolution.

[0092] S4. When the tool tip radius is greater than 0 mm, the instantaneous cutting layer relationship of the outer surface of a large titanium alloy component is as follows: Figure 7 As shown, the maximum residual height and tangent point s' formed by the intersection of two arc edges r , get the critical value of feed rate f s'r for::

[0093]

[0094] In the formula, r ε is the tool tip radius, s r is the point of contact between the cutting edge s and the tool tip arc, s' r It is the point of tangency between the tool's secondary cutting edge s' and the tool tip arc;

[0095] When the feed rate is less than the critical value f s'r hour:

[0096] When the feed rate is greater than the critical value f s'r hour:

[0097]

[0098] In the formula, The feed rate is less than the critical value f s'r The maximum residual height is The feed rate is greater than the critical value f s'r Maximum residual height at 100°;

[0099] According to equations (4), (5), (9) and (10), the initial main deflection angle κ of the tool is r0 are 95°, corresponding to the tool tip angle ε r The comparison results of the maximum residual height calculation results of the outer surface of large conical components with diameters of 400mm to 900mm are shown in Table 1 when the tool nose arc is 80° and the tool nose arc is 0.4mm and 0mm.

[0100] Table 1 Comparison of the calculation results of the maximum residual height of the turning surface under different tool nose arc radii

[0101]

[0102] From Table 1, when the tool nose arc radius is 0 mm, the selection of feed per revolution and the maximum residual height calculation need to consider the influence of the primary and secondary cutting edges. When the tool nose arc radius is greater than 0 mm, the selection of feed per revolution and the maximum residual height calculation should consider the influence of the tool nose arc radius and the primary and secondary cutting edges respectively.

[0103] Compared with the maximum residual height of the machined surface with a tool tip arc radius of 0 mm, when the tool tip arc radius increases to 0.4 mm, the maximum residual heights of the upper and lower end surfaces and the outer conical surface are reduced by 71.8%, 71.8% and 95.4% respectively, and the consistency of the maximum residual height distribution of the three machined surfaces is significantly improved.

[0104] Implementation Example 5: Correction of the maximum residual height of the machining surface and design of the turning process for large conical surface components.

[0105] S5. Based on the above analysis results, the cutting parameter scheme with a tool tip arc radius of 0.4 mm in Table 1 was adopted to carry out the turning experiment on the outer surface of large conical surface components with diameters ranging from 400 mm to 900 mm, and the experimental results of the maximum residual height of the machined surface were obtained, as shown in Table 2.

[0106] Table 2 Experimental results of maximum residual height of turning surface

[0107]

[0108] Comparing Table 1 and Table 2, the maximum residual height distributions of the upper and lower end faces and the outer conical surface show similar characteristics. The use of formula (9) and formula (10) can reveal the influence of the cone angle of the machined surface on the maximum residual height of the machined surface, but the solution results are significantly smaller than the experimental results, and the solution errors are 59.84%, 72.77% and 145.14% respectively.

[0109] According to the calculation results, the maximum residual height of the machining surface is corrected:

[0110] h' max =k α ×h max (27)

[0111] Among them, when the cone angle of the machined surface is -90°, the correction coefficient k α When the taper angle of the machined surface is 33°, the correction factor k α is 2.451.

[0112] Using equations (9) to (11), the maximum residual heights of the three surfaces with a tool tip arc radius of 0.4 mm are calculated, as shown in Table 3.

[0113] Table 3 Calculation results of maximum residual height of machined surface

[0114]

[0115] From Table 2 and Table 3, the maximum residual heights of the upper and lower end faces and the outer conical surface obtained by using formula (9) to formula (11) have an error of less than 6% between the calculated results and the experimental results, and their distributions show similar characteristics. The above model and method can be used for the calculation of the maximum residual height of the machining surface and the design of process solutions.

[0116] From Table 3, the maximum residual heights of the upper and lower end faces and the outer conical surface cut by this process scheme differ by 48.73%, and the distribution consistency is poor, which cannot meet the requirements of surface quality consistency.

[0117] To this end, using equations (1) to (3) and (5) to (11), with the maximum allowable residual height of the outer surface of the component and the absence of cutting interference as constraints, the initial main deflection angle, tool tip angle, tool tip arc radius and feed per revolution of the tool as process design variables, and the best consistency of the maximum residual height of the outer surfaces of multiple components as the goal, a process design method for turning large conical surface components is proposed, as shown in Figure 8 As shown. Among them, [h max ] is the maximum allowable residual height of the component outer surface, [δ hmax ] is the maximum allowable value of the component outer surface maximum residual height distribution consistency evaluation index.

[0118] use Figure 8 The method was used to obtain the process scheme for turning the upper and lower end faces and outer conical surface of large conical surface components, as shown in Table 4.

[0119] Table 4 Process scheme for turning the outer surface of large conical components

[0120]

[0121] The maximum residual height of the machined surface and its distribution consistency of Examples 1 and 2 both meet the quality requirements of the machined surface. Compared with the process schemes in Table 3, the maximum residual height of the machined surface of Scheme 1 is significantly reduced, and its distribution consistency is improved by 84.38%.

[0122] The maximum residual height of the machined surface of Example 2 is increased, and its distribution consistency is improved by 99.16%.

[0123] In Example 1, although the maximum residual heights of the three machined surfaces increased by 48.3%, 48.3% and 43.8% respectively when cutting with Example 2, the difference between the maximum residual heights of the machined surfaces was significantly reduced, and the material removal rate was increased by 30%, 30% and 37.5% respectively. Therefore, under the premise of meeting the requirements of the maximum residual height and the roughness of the machined surface of the component, Scheme 2 has obvious advantages in the consistency of the machined surface quality and the machining efficiency.

[0124] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A design method for the residual height turning process of large conical surface components. Features: The steps include: S1. First, calculate the maximum residual height of the lower and upper end faces and the outer conical surface of the turning conical surface component, the tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively: k s =270°-(a+k) r0 ),k s ′=270°-(α+κ r0 +e r ) (1) In the formula, κ r0 is the initial cutting edge angle of the tool, κ s is the angle between the cutting edge s of the tool and the feed direction along the clockwise direction, κ s ' is the angle between the cutting edge s' of the tool and the feed direction along the clockwise direction, α is the taper angle of the machined surface, v fs is the feed speed along the cutting edge s direction of the tool, v fs ' is the feed speed along the cutting edge s' direction of the tool, ε r is the tip angle, v f ' is the feed speed in the interference zone between the tool and the workpiece determined by the tool cutting edges s and s'; Tool cutting edge s, cutting edge s' and tool feed speed v f The angle κ s , κ s 'Respectively: In the formula, ε r is the blade tip angle, κ r is the main deflection angle of the tool when working, κ r ' is the tool deflection angle, κ s ' is the angle between the cutting edge s' and the feed direction in the clockwise direction, κ s is the angle between the tool cutting edge s and the feed direction along the clockwise direction, and the feed direction in the interference zone between the tool and the workpiece is determined by s and s'; When the tool cuts the outer surface of the component, the maximum residual height h max for: Where α is the cone angle of the machined surface, κ r0 ' is the initial tool deflection angle, κ r0 is the initial cutting angle of the tool, ε r is the tool tip angle, f is the feed rate per revolution of the workpiece, h max is the residual height; Among them, the value range of the machined surface cone angle α is: 90° - κ r0 <α<270° - (κ r0 + ε r ), or - 90° - κ r0 <α<90° - (κ r0 + ε r )(3) Where α is the cone angle of the machined surface, κ r0 ' is the initial tool deflection angle, κ r0 is the initial cutting angle of the tool, ε r is the knife tip angle; S2. According to the parameters calculated in step S1, the taper angle of the machined surface and the influence on the maximum residual height of the machined surface are analyzed. During the tool cutting process, the taper angle of the machined surface that interferes with the workpiece is: 90°-(k r0 +e r )<α<90°-κ r0 (4) Where α is the cone angle of the machined surface, κ r0 is the initial cutting angle of the tool, ε r is the knife tip angle; S3. According to the data parameters of the tool and large conical surface component processing calculated in step S1, the maximum residual height consistency of the upper and lower end faces and the outer conical surface is solved. The solution method for the consistency of the maximum residual height of the upper and lower end faces and the outer conical surface is: In the formula, i and j are the outer surfaces of components with different machined surface taper angles, Δh max is the maximum residual height difference between the outer surfaces of components i and j, h maxj (α j ,κ r0j ,ε rj ,f j ) is the minimum value of the maximum residual height on the outer surface of the component, δ hmax It is an evaluation index for the consistency of the maximum residual height distribution on the outer surface of a component, and is used to obtain the cutting process parameters that achieve the best consistency of the maximum residual height distribution on the outer surfaces of two components; S4. When the tool tip radius is greater than 0 mm, the instantaneous cutting layer relationship of the outer surface of a large titanium alloy component is obtained by using the maximum residual height and tangent point s' formed by the intersection of two arc edges. r , get the critical value of feed rate f s'r for: f s'r =2×r ε sin(k r ′) (6) In the formula, r ε is the tool tip radius, s r is the point of contact between the cutting edge s and the tool tip arc, s' r It is the point of tangency between the tool's secondary cutting edge s' and the tool tip arc; When the feed rate is less than the critical value f s'r hour: When the feed rate is greater than the critical value f s'r hour: In the formula, The feed rate is less than the critical value f s'r The maximum residual height of the machined surface is The feed rate is greater than the critical value f s'r The maximum residual height of the machined surface; The initial cutting edge angle κ of the tool is used r0 are 95°, corresponding to the tool tip angle ε r When the tool radius is 80° and the tool tip radius is 0.4mm and 0mm, the maximum residual height calculation results of the outer surface of large conical components with a diameter of 400mm to 900mm are compared; S5. Based on the analysis results of steps S1, S2, S3, and S4, the cutting parameters of the tool tip arc radius of 0.4 mm are used to verify the outer surface of the large conical surface component with a turning diameter of 400 mm to 900 mm, and the maximum residual height of the machined surface is obtained. Based on the verification results, the maximum residual height of the machined surface is corrected: h max '=k α ×h max (9) In the formula, h max ' is the maximum residual height of the machined surface after correction, k α is the correction factor; Among them, when the cone angle of the machined surface is -90°, the correction coefficient k α is 1.

663. When the taper angle of the machined surface is 33°, the correction coefficient k α It is 2.451, and the maximum residual height of the upper and lower end faces and the outer conical surface is obtained.

2. A method for designing a turning process for a residual height of a large conical surface component according to claim 1, Features: Formula (4) and Formula (5) in step S1 are the influence of the initial main rake angle of the tool, the tool tip angle, and the taper angle of the machined surface on the maximum residual height by the feed rate per revolution.

3. A method for designing a turning process for a residual height of a large conical surface component according to claim 2, Features: The formula (4) and formula (5) used in step S1 are used to obtain the maximum residual height h of the outer surface of the large titanium alloy component when the two tools are turned. max Curve of feed rate f per revolution, where the initial main deflection angles κ of the two tools r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, the inner diameter of the component is 400mm to 900mm, and the cone angles of the machined surfaces of the lower and upper end faces and the outer conical surface of the component are -90° and 33° respectively.

4. A method for designing a turning process for a residual height of a large conical surface component machining surface as claimed in claim 3, Features: Formula (6) in step S2 is that the initial main deflection angle of the tool and the tool nose angle directly affect the size of the interference area between the tool and the workpiece. Formula (6) is used to determine whether cutting interference occurs when the selected tool cuts the outer surface of the component with different machining surface taper angles, and to obtain the maximum residual height h of the outer surface of the large titanium alloy component when turning. max Curve of the machined surface taper angle α and tool cutting interference area, where the initial main deflection angles κ of the two tools r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, and the feed rate per revolution f is 0.1mm / r.

5. A method for designing a turning process for a residual height of a large conical surface component machining surface as claimed in claim 4, Features: The equations (4) and (7) in step S2 obtain the maximum residual height consistency relationship diagram of the upper and lower end faces and the outer conical surface of the large titanium alloy component, where the initial main deflection angles κ of the two tools are r0 They are 95° and 93° respectively, corresponding to the tool tip angle ε r They are 80° and 55° respectively, and the feed rate f per revolution is 0.08mm / r, 0.09mm / r and 0.10mm / r respectively.

6. A method for designing a turning process for a residual height of a large conical surface component according to claim 1, Features: The formula (4), formula (5) in step S1 and formula (9), formula (10) in step S4 are used to calculate the initial main deflection angle κ of the tool: r0 are 95°, corresponding to the tool tip angle ε r The comparison results of the maximum residual height calculation results of the outer surface of large conical components with diameters of 400mm to 900mm are shown when the angle is 80° and the tool nose arc is 0.4mm and 0mm.

7. A method for designing a turning process for a residual height of a large conical surface component according to claim 1, Features: Formula (9) and Formula (10) in step S4 are used to calculate the maximum residual height of three surfaces with a tool tip arc radius of 0.4 mm, the maximum residual height of the upper and lower end surfaces and the outer conical surface, and the error between the calculated results and the experimental results is less than 6%.

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