Design method and system of a six-blade and three-blade equidistribution over-center anti-shock ball end mill

Abstract

The application provides a design method and system of a six-blade and three-blade equidistribution over-center anti-vibration ball head milling cutter, relates to the technical field of machining, and the method comprises the following steps: step 1, a multi-blade equidistribution strategy is adopted, six main cutting edges are uniformly arranged around the cutter axis, the cutting path of each edge intersects in the center area of the cutter, and the initial geometric configuration of the ball head milling cutter is formed; step 2, based on the initial geometric configuration, the diameter ratio of the cutting head and the clamping section is set, the diameter of the clamping section is slightly larger than the diameter of the cutting head, a micro-inclination angle structure is introduced in the transition area, and the cutter base structure is generated; and step 3, the cutter base structure is introduced into a finite element analysis model, geometric and mechanical correlation analysis is carried out, and the edge structure adjustment parameters are obtained based on the analysis results. Through the six-blade structure and the equidistribution three-blade over-center layout, the application improves the cutting efficiency and the machining surface quality, and enhances the stability in the cutting process of the cutter to reduce vibration.

Description

Technical Field

[0001] This invention relates to the field of machining technology, and in particular to a design method and system for a ball end mill with six cutting edges, three of which are evenly distributed and pass through the center for vibration resistance. Background Technology

[0002] In the machining of integral titanium alloy bladed disks for aero-engines, traditional multi-flute ball end mills are mostly not specifically designed for center cutting stability, and rarely adopt a configuration where three flutes pass through the center to form an equilateral triangle for stable support. When machining the curved surface at the root of the blades of integral titanium alloy bladed disks, the cutting edges of traditional tools are difficult to form a balanced load-bearing point in the central area, and the cutting force tends to concentrate at the edge cutting edge. For example, when a traditional 6-flute non-uniformly distributed ball end mill is used to machine the R3mm arc surface at the root of the blade, due to the lack of a symmetrical structure with three flutes passing through the center, the force deviation of the tool during the cutting process reaches 8%-12%, which may cause slight radial runout of the tool. This results in the actual size of the arc surface at the blade root deviating from the design size, requiring subsequent machining correction.

[0003] Furthermore, the chip breaker design, cutting edge parameters, and overall vibration-resistant structure of traditional ball end mills are mostly not adjusted in conjunction with the special working conditions of impeller machining. Although some traditional tools have chip breaker grooves, they are mostly single axial grooves, and the groove spacing and groove depth are not matched with the tool helix angle and cutting parameters. Moreover, the transition area between the clamping section and the cutting head of traditional tools is mostly a straight section or a large-angle conical transition, without considering the use of shank diameter adaptation and micro-tilt angle to enhance rigidity. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a design method and system for a ball end mill with six cutting edges and three evenly distributed cutting edges for center-side anti-vibration, which adjusts the load distribution of the cutting edge to improve center cutting stability and enhance the overall rigidity and vibration resistance of the tool.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0006] A first aspect is a design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, the method comprising:

[0007] Step 1: Using a multi-edge distribution strategy, the six main cutting edges are evenly arranged around the tool axis, so that the cutting paths of each edge converge in the central area of ​​the tool, forming the initial geometric configuration of the ball end mill.

[0008] Step 2: Based on the initial geometric configuration, the diameter ratio between the cutting head and the clamping section is set so that the diameter of the clamping section is slightly larger than the diameter of the cutting head, and a micro-tilt structure is introduced in the transition area to generate the tool base structure;

[0009] Step 3: Import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results;

[0010] Step 4: Based on the adjustment parameters of the cutting edge structure, the main cutting edge is designed as a helical cutting edge structure in the finite element analysis model. The helical angle value is determined by combining the tool diameter and cutting conditions. The geometric features of the cutting edge are adjusted according to the finite element simulation results to generate the helical cutting edge structure.

[0011] Step 5: Place the spiral cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, arrange the chip breaking grooves in an alternating pattern on the surface of the cutting edge, and coordinate the distribution shape and contour size to form a cutting edge structure with chip breaking grooves.

[0012] Step 6: Based on the cutting edge structure with chip breaker grooves, the stress distribution and cutting load of the cutting edge are simulated and analyzed by finite element analysis model, and the width and spatial orientation parameters of the cutting edge are set to complete the comprehensive design of the anti-vibration ball end mill.

[0013] Secondly, a ball end mill design system with six flutes and three flutes evenly distributed over the center for vibration resistance includes:

[0014] The multi-edge uniform distribution configuration module is used to employ a multi-edge uniform distribution strategy to arrange the six main cutting edges evenly around the tool axis, so that the cutting paths of each edge converge in the central area of ​​the tool to form the initial geometric configuration of the ball end mill.

[0015] The tool base construction module is used to generate the tool base structure based on the initial geometry by setting the diameter ratio between the cutting head and the clamping section, making the diameter of the clamping section slightly larger than the diameter of the cutting head, and introducing a micro-tilt structure in the transition region.

[0016] The structural parameter generation module is used to import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results.

[0017] The spiral cutting edge design module is used to design the main cutting edge as a spiral cutting edge structure in the finite element analysis model based on the adjustment parameters of the cutting edge structure. It determines the spiral angle value by combining the tool diameter and cutting conditions, and adjusts the geometric features of the cutting edge according to the finite element simulation results to generate the spiral cutting edge structure.

[0018] The chip breaker integrated module is used to place the helical cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, chip breaker grooves are arranged in an interlaced pattern on the surface of the cutting edge, and the distribution shape and contour size are coordinated to form a cutting edge structure with chip breaker grooves.

[0019] The cutting edge parameter determination module is used to simulate and analyze the stress distribution and cutting load of the cutting edge based on the cutting edge structure with chip breaker groove through finite element analysis model, and to set the width and spatial orientation parameters of the cutting edge to complete the comprehensive design of the anti-vibration ball end mill.

[0020] Thirdly, a computing device includes:

[0021] One or more processors;

[0022] A storage device for storing one or more programs that, when executed by one or more processors, cause the one or more processors to implement the method.

[0023] Fourthly, a computer-readable storage medium storing a program that, when executed by a processor, implements the method.

[0024] The above-described solution of the present invention has at least the following beneficial effects:

[0025] The tool employs six main cutting edges evenly arranged at 60° circumference, distributing the load of a single cut across more cutting edges. Simultaneously, the convergence design of three edges passing through the center ensures no cutting blind spots in the tool's central area, avoiding localized load concentration caused by missing cutting from the central edge. This allows for full-edge participation in cutting, reducing instantaneous impact on the machine tool spindle and lowering energy consumption. Based on the tool diameter and cutting conditions, a helical cutting edge with a constant helix angle of 30°-45° is designed. Combined with precise control of the cutting edge width, this results in a smoother contact trajectory between the cutting edge and the workpiece during cutting, avoiding intermittent impacts during straight-edge cutting. In actual machining, the cutting vibration frequency can be controlled within a low-frequency stable range, reducing feed rate limitations caused by high-frequency vibration and improving machining efficiency and surface quality.

[0026] The cutting head and clamping section are designed with a diameter ratio of 0.8-0.95, making the clamping section diameter slightly larger than the head. Combined with a transition zone structure with a 1°-3° micro-tilt angle, a rigid layout with strong support at the rear and stable cutting at the front is formed, reducing tool chatter and tool runout error caused by vibration. Through geometric correlation analysis and constraint matching of the rake angle, clearance angle, and inclination angle, suitable cutting edge structure adjustment parameters are generated, so that the cutting angles of each cutting edge form a complementary anti-vibration effect. By appropriately increasing the clearance angle, the friction between the flank face and the machined surface of the workpiece is reduced, and the vibration excitation source is reduced. At the same time, the adjustment of the inclination angle can change the direction of the cutting force, converting radial vibration into axial controllable force, improving the tool's anti-vibration stability. The chip breaking grooves arranged alternately along the helical cutting edge, combined with the helix angle and cutting parameters to coordinate the groove shape size and distribution spacing, can break the chips into short chips according to the preset trajectory, avoiding local overheating and wear caused by long chips wrapping around the cutting edge. Through precise control of the cutting edge width and spatial orientation, the cutting edge sharpness is ensured while enhancing the cutting edge's impact toughness. Attached Figure Description

[0027] Figure 1 This is a flowchart illustrating a design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, provided by an embodiment of the present invention.

[0028] Figure 2 This is a schematic diagram of a ball end mill design system with six flutes and three flutes evenly distributed over the center for vibration resistance, provided by an embodiment of the present invention. Detailed Implementation

[0029] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0030] like Figure 1 As shown, an embodiment of the present invention proposes a design method for a ball end mill with six flutes and three flutes evenly distributed over the center for vibration resistance. The method includes the following steps:

[0031] Step 1: Using a multi-edge distribution strategy, the six main cutting edges are evenly arranged around the tool axis, so that the cutting paths of each edge converge in the central area of ​​the tool, forming the initial geometric configuration of the ball end mill.

[0032] Step 2: Based on the initial geometric configuration, the diameter ratio between the cutting head and the clamping section is set so that the diameter of the clamping section is slightly larger than the diameter of the cutting head, and a micro-tilt structure is introduced in the transition area to generate the tool base structure;

[0033] Step 3: Import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results;

[0034] Step 4: Based on the adjustment parameters of the cutting edge structure, the main cutting edge is designed as a helical cutting edge structure in the finite element analysis model. The helical angle value is determined by combining the tool diameter and cutting conditions. The geometric features of the cutting edge are adjusted according to the finite element simulation results to generate the helical cutting edge structure.

[0035] Step 5: Place the spiral cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, arrange the chip breaking grooves in an alternating pattern on the surface of the cutting edge, and coordinate the distribution shape and contour size to form a cutting edge structure with chip breaking grooves.

[0036] Step 6: Based on the cutting edge structure with chip breaker grooves, the stress distribution and cutting load of the cutting edge are simulated and analyzed by finite element analysis model, and the width and spatial orientation parameters of the cutting edge are set to complete the comprehensive design of the anti-vibration ball end mill.

[0037] In this embodiment of the invention, the initial configuration design with six equally distributed cutting edges converging at the center distributes the cutting load evenly across the six main cutting edges, reducing local wear on the cutting edges and extending the stable time of a single cut. Furthermore, it allows the cutting paths of each edge to converge in the central region, reducing the common blind zone in ball end mills. This eliminates the need for additional cutting, enabling full-area cutting of the ball end without additional tooling. This simplifies the machining process, avoids workpiece dimensional errors caused by missed cuts in blind zones, and improves machining integrity and efficiency. The slightly thicker diameter of the clamping section compared to the cutting head enhances the connection rigidity between the tool and the machine tool clamping area, reducing radial wobble of the tool during machining. Simultaneously, the micro-tilt structure of the transition zone avoids stress concentration issues that easily arise from the right-angle transition between the head and the clamping section, reducing the risk of the base material fracture due to stress concentration during high-speed cutting and improving the overall impact resistance of the tool.

[0038] By studying the geometric correlation of characteristic parameters and adjusting parameter generation, key parameters such as the rake angle, clearance angle, and inclination angle of the cutting edge can be mutually adapted, avoiding performance contradictions caused by optimizing a single parameter. For example, it avoids the problem of increasing the rake angle to pursue cutting sharpness while ignoring the problem of increased friction on the flank face due to insufficient clearance angle. Through the coordinated matching between parameters, it ensures that the cutting edge can effectively cut into the workpiece while reducing unnecessary friction with the workpiece, balancing cutting efficiency and structural stability, and making the cutting edge performance more balanced. By adapting the helix angle to the tool diameter and cutting conditions, the main cutting edge contacts the workpiece with a helical trajectory, making the cutting process smoother, reducing the instantaneous impact between the tool and the workpiece, and reducing machining vibration. Furthermore, by adjusting the cutting edge geometry in combination with the cutting edge size and cutting trajectory, the contact state between the cutting edge and the workpiece is further optimized, avoiding problems such as poor chip removal and easy chipping of the cutting edge caused by an excessively wide or narrow cutting edge, achieving continuous and stable cutting, which can both protect the cutting edge and improve the smoothness of the machined workpiece surface.

[0039] In a preferred embodiment of the present invention, step 1 above, employing a multi-edge distribution strategy, arranges six main cutting edges evenly around the tool axis, so that the cutting paths of each edge converge in the central region of the tool, forming the initial geometric configuration of the ball end mill, and may include:

[0040] In this embodiment of the invention, step 110, based on a multi-edge distribution strategy, determines the circumferentially distributed positions of the six main cutting edges at the ball end, such that the circumferential angle between adjacent cutting edges is 60 degrees, to obtain the circumferential positioning result of each cutting edge. Specifically, this includes: determining the reference axis for circumferential positioning using the axis of the ball end mill, i.e., the central axis of the tool, and the geometric center line passing through the ball end and the tool holder as the reference axis; considering the outer circumference of the ball end as a closed annular surface with a circumferential angle range of 0 degrees to 360 degrees; and arranging six main cutting edges on this annular surface. The cutting edges are required to be evenly distributed in the circumferential direction, meaning that the angles formed by any two adjacent cutting edges and the axis are equal. Since six main cutting edges need to be arranged and the total circumferential angle is 360 degrees, the circumferential angle between two adjacent cutting edges needs to be calculated by dividing the total angle by the number of cutting edges. Specifically, divide 360 ​​degrees by 6 to get a circumferential angle of 60 degrees between each adjacent cutting edge. This angle must be ensured to be the angle along the tangent direction of the circumference, rather than the angle corresponding to the straight-line distance, in order to conform to the circumferential characteristics of the spherical surface.

[0041] The circumferential positions of each cutting edge are determined one by one. A fixed position at the end of the ball end is selected as the starting reference. For example, the radial extension line directly in front of the ball end is taken as the 0-degree reference line. This reference line must be perpendicular to the tool axis and pass through the ball end. The circumferential position of the first main cutting edge is set at the 0-degree reference line, and the radial plane angle formed with the axis is 0 degrees. The second main cutting edge starts from the 0-degree reference line and rotates 60 degrees clockwise or counterclockwise along the circumference. The angle formed by its radial plane with the axis is... The first cutting edge is 60 degrees; the second cutting edge rotates another 60 degrees from the second position, resulting in an angle of 60 degrees + 60 degrees = 120 degrees; the third cutting edge continues to rotate 60 degrees, resulting in an angle of 120 degrees + 60 degrees = 180 degrees; the fifth cutting edge rotates to 180 degrees + 60 degrees = 240 degrees; the sixth cutting edge rotates to 240 degrees + 60 degrees = 300 degrees; after positioning, the angle between the sixth cutting edge and the first cutting edge needs to be verified, 360 degrees - 300 degrees = 60 degrees, which is consistent with the other adjacent angles, ensuring that the six positions form a uniform distribution of 0 degrees, 60 degrees, 120 degrees, 180 degrees, 240 degrees, and 300 degrees, thus completing the circumferential positioning.

[0042] Step 111: Based on the circumferential positioning results, calculate the radial and axial coordinates of each main cutting edge, controlling the extension trajectory of each edge from the outer edge of the ball end mill towards the tool axis, converging in the central area of ​​the ball end mill, and generating corresponding cutting edge line data. Specifically, this includes: determining the core parameters of the ball end mill, the ball end mill radius, the ball center located on the tool axis, and the axial distance R from the ball end tip (i.e., the axial length R from the ball end tip to the ball center); and calculating the radial coordinates point-by-point. The radial coordinate refers to the straight-line distance from a point on the cutting edge to the tool axis, i.e., the distance from the projection of that point onto the axis in a plane perpendicular to the axis. For each main cutting edge, the calculation starts from the outer edge of the ball end mill, which is a spherical surface. The radial coordinate of the point furthest from the axis is equal to the radius R of the ball head. Since the distance from this point to the center of the ball is R, and the center of the ball lies on the axis, the distance from this point to the axis is also R. When extending from the outer edge towards the tool axis, multiple consecutive points need to be selected on the cutting edge trajectory. For example, a point can be selected at 0.1mm axial intervals to ensure a smooth trajectory. The radial coordinate of each point must satisfy the spherical geometry. The square of the radial coordinate of this point plus the square of the axial distance from this point to the center of the ball is equal to the square of the radius R of the ball head. For example, if the axial distance from a point to the center of the ball is a, and the direction along the axis is negative from the center of the ball to the top of the ball head and positive from the direction towards the tool holder, then the radial coordinate b of this point must satisfy b 2 +a 2 =R 2 Therefore, the size of b changes with the change of a. When a is 0, that is, the center of the ball, b = R; when a increases, it moves towards the tool holder and b decreases; when b is close to 0, it moves closer to the axis and a is close to R.

[0043] The axial coordinates are calculated point by point, with the apex of the ball head as the origin (0 point). The positive direction is along the tool axis towards the tool holder. The axial coordinate of the ball center is +R, since the axial distance from the apex of the ball head to the center is R. The axial coordinate of the outer edge of the ball head is (+R), since the outer edge is on the spherical surface and the axial distance to the center is 0, meaning it is in the same axial position as the center. Extending from the outer edge towards the axis, the axial coordinate of each point is the axial coordinate of the center and the axial distance a from that point to the center, i.e., +R + a. For example, if the axial distance a from a point to the center is +0.5mm (towards the tool holder), then its axial coordinate is R + 0.5mm; if a is -R (i.e., at the apex of the ball head), then the axial coordinate is R + (-R) = 0mm. When the cutting edge extends to the central region, the radial coordinate needs to be gradually reduced to close to 0, for example, less than 0.1mm. At this time, the corresponding axial coordinate is R + Since b is close to 0, the axial coordinate is close to R+R=2R, ensuring that the six cutting edges meet at this point. To generate the cutting edge data, for each main cutting edge, calculate the radial coordinate (b) and axial coordinate (R+a) of at least 20 consecutive points according to the above method, and record the circumferential angle of each point. Arrange these points in order of axial coordinate from 0 (top of the ball head) to 2R (center area) to form a continuous spatial curve trajectory, which is the cutting edge data of the cutting edge. Finally, verify the cutting edge data of the six cutting edges. In the center area, where the axial coordinate is close to 2R and the radial coordinate is close to 0, the endpoints of the six cutting edges must coincide or the spacing must be less than 0.05mm to ensure accurate meeting.

[0044] Step 112: Based on the cutting edge line data, construct the rake face geometry for each cutting edge, and design the rake face geometry based on the rake face geometry to form a complete cutting edge unit. Specifically, this includes: using the cutting edge line generated in Step 111 as a reference, the rake face is a curved surface located outside the cutting edge line, away from the tool center. Its function is to reduce friction with the machined surface of the workpiece during cutting. Determine the key parameters of the rake face, the clearance angle, which is the angle between the rake face and a plane perpendicular to the cutting direction, typically set to 5°-10° according to the hardness of the material being processed. Generate the rake face point by point. On the flank face, at each point on the cutting edge, along the outer direction perpendicular to the cutting edge, determine a corresponding point on the flank face according to the clearance angle. The distance between this point and the point on the cutting edge is 0.5-1mm to ensure that the flank face has sufficient strength. For example, if the clearance angle is 8°, the point on the flank face needs to be tilted outward by 8° and maintain a set distance from the point on the cutting edge. Connect all the points on the flank face to ensure that the line connecting adjacent points is smooth, that is, the curvature of the line connecting any three consecutive points is consistent, forming a flank face that fits the cutting edge and has a tapered gradient overall. The flank face near the top of the ball head is slightly narrower and gradually widens towards the shank.

[0045] The matching design of the rake face geometry is crucial. The rake face, located inside the cutting edge (closest to the tool center), guides chip removal and needs to form a sharp cutting edge with the flank face at the cutting edge. Key parameters of the rake face are determined, including the rake angle (the angle between the rake face and a plane parallel to the cutting direction), typically between 3° and 8°, set according to chip removal requirements. The rake face is generated point-by-point. At each point on the cutting edge, along a direction perpendicular to the cutting edge, a corresponding point on the rake face is determined according to the rake angle inclination. This point is 0.3-0.8mm away from the cutting edge point, ensuring a reasonable wedge angle with the flank face. For example, if the rake angle is 5°, the point on the rake face needs to be tilted inwards by 5° and maintain a set distance from the cutting edge point. The rake face is then adjusted to match the flank face, and the rake face is checked. The angle (wedge angle) between the rake face and the clearance face at the cutting edge must be between 60° and 80°. If the angle is not correct, the rake angle or clearance angle needs to be finely adjusted until the requirements are met. Connect all rake face points to ensure a smooth connection. As the rake face extends towards the tool holder, the distance between it and the clearance face gradually increases, forming a chip evacuation groove. The formation of a complete cutting edge unit integrates the cutting edge, clearance face, and rake face of the same main cutting edge. The cutting edge serves as the intersection line between the clearance face and the rake face. It is necessary to ensure that the three transition smoothly (without sharp edges) at the intersection line. Check the integrity of the unit, verify whether the clearance face covers the full length of the cutting edge, whether the chip evacuation groove of the rake face is continuous, and whether the cutting edge is sharp. The radius of the fillet at the intersection line of the rake and clearance faces should be less than 0.02mm. After confirming that there are no errors, an independent cutting edge unit is formed.

[0046] Step 113 involves axially superimposing the six cutting edge units evenly distributed circumferentially to form the initial geometric configuration of the ball end mill. Specifically, this includes: assigning the six cutting edge units generated in step 112 to the circumferential positions (0 degrees, 60 degrees, 120 degrees, 180 degrees, 240 degrees, and 300 degrees) determined in step 110; rotating each unit around the tool axis (the rotation angle is equal to its circumferential position angle) to ensure that the circumferential angle of the cutting edge of each unit is consistent with the positioning result. For example, the unit at the 60-degree position needs to be rotated 60 degrees clockwise around the axis to ensure that its circumferential angle of the cutting edge coincides with the preset position; checking the arrangement accuracy; and measuring the circumferential angle between the cutting edges of adjacent units, which must be strictly equal to 60 degrees (with an error not exceeding ±0.1 degrees) to ensure accurate and even distribution.

[0047] The specific operation of axial stacking involves integrating six units into one along the tool axis, from the ball end to the tool holder. This ensures that each unit is aligned axially. Using the ball end as the axial reference point (axial coordinate 0), the axial position of each unit is adjusted. Corresponding points on the ball ends of all units must coincide at point 0, and the axial coordinates of the cutting edges must be completely consistent. For example, if the axial coordinate of a point on the cutting edge of one unit is 5mm, the axial coordinates of the cutting edge points at the same position in other units must also be 5mm to avoid interference and gaps. During stacking, it is necessary to check whether the flank and rake faces of adjacent units overlap. The overlap must be less than 0.01mm, and there should be no excessive gaps. The error must be less than 0.1mm. If there is overlap, fine-tune the circumferential angle of the unit (within ±0.05 degrees). If there is a gap, fill it by optimizing the edge curves of the front and rear cutting faces. Verify the center intersection and confirm whether the intersection point of the cutting lines of the six units in the central area (around 2R in the axial coordinate) coincides (error less than 0.03mm). Ensure that there is no cutting blind zone at the center of the ball end mill. After the stacking is completed, check the symmetry of the tool as a whole. Rotate 60 degrees around the axis. The geometry of the tool must be consistent with that before the rotation (error less than 0.02mm). Confirm that the structure of all cutting edge units is complete and there is no interference. The ball end surface transitions smoothly, and finally the initial geometric configuration of the ball end mill is formed.

[0048] The six main cutting edges are evenly distributed circumferentially at 60 degrees, ensuring that the cutting force on each edge is uniformly distributed in the circumferential direction during the cutting process. This reduces vibration and runout of the tool caused by uneven force distribution, improving machining stability. The trajectory design of each cutting edge converging from the outer edge of the ball end to the central area ensures that the entire area of ​​the ball end is covered by the cutting edge, avoiding blind spots and improving material removal efficiency. Accurate calculation of radial and axial coordinates ensures accurate cutting edge data. Combined with the matching design of the rake and flank faces, the geometric accuracy of the cutting edge is guaranteed, thereby improving the dimensional accuracy and surface finish of the machined surface. The matching design of the flank and rake faces forms a reasonable wedge angle, enhancing the structural strength of the cutting edge. At the same time, the axial superposition of the six cutting edge units increases the overall rigidity of the tool and extends its service life. The rake face, based on the matching design of the flank face, forms a smooth chip removal channel, facilitating timely chip removal, reducing friction and heat accumulation of chips in the cutting area, and reducing the risk of tool wear and workpiece surface damage. The symmetry and integrity of the initial geometric configuration enable the tool to maintain stable performance at different cutting angles and depths, making it suitable for machining complex curved surfaces.

[0049] In a preferred embodiment of the present invention, step 2 above, based on the initial geometric configuration, involves setting the diameter ratio between the cutting head and the clamping section so that the diameter of the clamping section is slightly larger than the diameter of the cutting head, and introducing a micro-tilt structure in the transition region to generate the tool base structure. This step may include:

[0050] In this embodiment of the invention, step 220, based on the initial geometric configuration, sets the ratio range of the maximum diameter of the cutting head to the diameter of the clamping section to be 0.8 to 0.95. Based on this ratio and the diameter of the cutting head, the specific diameter of the clamping section is calculated to form diameter parameters. Specifically, this includes: determining the specific measurement of the maximum diameter of the cutting head; from the generated initial geometric configuration, determining the cutting head as the region containing the ball end, the main cutting edge, and the cutting edge band, i.e., the part of the tool that participates in cutting; when measuring the maximum diameter of this region, at least 5 evenly distributed radial sections need to be selected along the tool axis direction, for example, from the top of the ball end towards the tool holder, each... Take a cross-section every 5mm and measure the maximum distance perpendicular to the axis within each cross-section, which is the diameter of that cross-section. The largest value is the maximum diameter of the cutting head. For example, if the diameters of five cross-sections are 9.8mm, 10.0mm, 9.9mm, 9.7mm, and 9.6mm, the maximum diameter of the cutting head is determined to be 10.0mm. The selection of the diameter ratio range is based on the range of 0.8 to 0.95. The specific selection depends on the machining requirements. If the material being machined is a high-strength alloy (such as titanium alloy or nickel-based alloy), the cutting force is large, and higher rigidity is required, then a range of 0.8 to 0.95 is preferred. A ratio of 9 (coarser clamping section); if machining low-strength materials such as aluminum alloys, where cutting forces are small, and tool flexibility needs to be considered, a ratio of 0.9 to 0.95 should be selected (coarser clamping section is sufficient); the specific process for determining the ratio, taking a cutting head with a maximum diameter of 10.0mm as an example, if machining titanium alloys (requiring high rigidity), a ratio of 0.85 is initially selected. In this case, the clamping section diameter is calculated as 10.0mm ÷ 0.85 ≈ 11.76mm; standard adaptation adjustment of the clamping section diameter is necessary because machine tool chucks are usually adapted to standard diameters (such as 6mm, 8mm, 10mm, 12mm, 16mm, etc.). Check if the calculation result is the standard value. The above 11.76mm is close to the standard value of 12mm. Therefore, the ratio is adjusted by reverse calculation. The new ratio = maximum diameter of the cutting head ÷ standard clamping section diameter = 10.0mm ÷ 12mm ≈ 0.83. This value is within the range of 0.8 to 0.95, which meets the requirements. Finally, the clamping section diameter is determined to be 12mm and the ratio is 0.83. The final confirmation of the diameter parameters is to record the maximum diameter of the cutting head (10.0mm), the clamping section diameter (12mm), and the ratio between the two (0.83) as the diameter parameters to ensure the logical consistency between the parameters. 10.0 ÷ 12 ≈ 0.83.

[0051] Step 221: Based on the diameter parameters, design a micro-tilt structure with an inclination angle of 1° to 3° in the transition zone between the head and the clamping section, generating the geometric parameters of the transition zone. Specifically, this includes: the positioning and range of the transition zone. The transition zone is the connecting part between the cutting head and the clamping section. Its starting end is the axial position where the maximum diameter of the cutting head is located, i.e., the cross-sectional position measured to a diameter of 10.0 mm. Its ending end is the starting position of the clamping section, which needs to be compatible with the clamping range of the machine tool chuck. It is typically 20–50 mm from the end of the tool shank. The selection logic for the micro-tilt angle range is as follows: the inclination angle is set to 1° to 3°. The specific selection must meet two conditions: the length of the transition zone does not exceed 20% of the total tool length (to avoid…). (Excessive tool length affects rigidity); the slope of the transition zone is sufficiently gentle to avoid abrupt diameter changes (slope = diameter difference ÷ transition zone length, must be ≤0.1mm / mm); the specific tilt angle is determined by taking a maximum cutting head diameter of 10.0mm and a clamping section diameter of 12mm as an example, the diameter difference = 12mm - 10.0mm = 2mm (total difference on both sides), and the diameter difference on one side is 1mm, that is, the generatrix of the transition zone needs to extend 1mm outward from the cutting head to the clamping section; if the total tool length is limited to 150mm, the transition zone length must be ≤30mm (150mm × 20%), so 2° is chosen as the tilt angle, 1° will cause the transition zone to be too long, and 3° may exceed the slope limit.

[0052] The precise calculation of the transition zone length requires that the single-sided diameter difference = transition zone length × tangent of the tilt angle. Given that the tangent of a 2° tilt angle is approximately 0.0349, without needing a formula, it can be understood that for every 100mm of length, the single-sided diameter increases by 3.49mm. Therefore, the transition zone length ≈ single-sided diameter difference ÷ 0.0349 = 1mm ÷ 0.0349 ≈ 28.65mm. For ease of machining, we round it to the nearest integer, 29mm. At this point, we verify that the single-sided diameter difference = 29mm × 0.0349 ≈ 1.01mm, with an error of only 0.01mm from the target of 1mm, meeting the requirements. Therefore, the transition zone length is determined to be 29mm. A complete record of the transition zone geometric parameters is required, including: tilt angle 2°, transition zone length 29mm, starting end diameter 10.0mm (consistent with the maximum diameter of the cutting head), ending end diameter 12mm (consistent with the diameter of the clamping section), starting end axial position (at the maximum diameter section of the cutting head), and ending end axial position (29mm from the starting end towards the tool holder).

[0053] Step 222: Based on the diameter parameters and transition zone geometric parameters, geometrically integrate the micro-tilt structure with the cutting head and clamping section to form a complete tool base structure. Specifically, this includes: locating the starting end of the transition zone, ensuring the starting end cross-section of the transition zone completely coincides with the maximum diameter cross-section of the cutting head, with consistent axial position and diameter, ensuring both are on the same radial plane, and matching surface curvature. Measure the surface curvature of the cutting head end near the transition zone. For example, if the curvature of this area corresponds to a radius of 8mm, adjust the surface curvature of the starting end of the transition zone to also be 8mm, ensuring a smooth transition at the connection point. Use a feeler gauge to check for gaps. The gap must be ≤0.01mm; for the connection calibration between the transition zone and the clamping section, locate the end of the transition zone, and make the end section of the transition zone coincide with the starting section of the clamping section. The axial position is the starting end +29mm, and the diameter is 12mm. Ensure that the straight shank of the clamping section starts from this section, and the axis is completely coincident with the axis of the transition zone. The coaxiality error is ≤0.005mm. The end curvature transition is necessary. The clamping section is a straight shank with an infinite radius of curvature. The end of the transition zone needs to gradually transition from an inclined curved surface to a straight shank. By adjusting the curvature of the last 5mm length of the curved surface at the end, the curvature of the transition zone gradually increases to infinity, ensuring that there are no obvious sharp edges at the connection and no protrusions when touched with a finger.

[0054] Overall continuity verification and diameter variation verification were performed. Starting from 10.0 mm, the diameter increased by approximately 0.0349 mm for every 1 mm extension along the axis, corresponding to a 2° tilt angle. After 29 mm, the diameter increased to 12 mm. There were no sudden increases or decreases in diameter throughout the process. Axis consistency verification was performed using a laser diameter gauge along the tool axis to ensure that the axial deviation of the cutting head, transition zone, and clamping section was ≤0.003 mm, avoiding tool eccentricity. The final formation of the tool base structure was achieved after confirming that all connection parts were smooth, parameters matched, and there were no stress concentration points. The geometry of the cutting head, transition zone, and clamping section was integrated to form a complete tool base structure, i.e., the main skeleton of the tool, excluding subsequent details such as cutting edges and chip grooves.

[0055] The diameter ratio of the cutting head to the clamping section, making the clamping section slightly thicker than the cutting head, enhances the tool's resistance to bending after clamping. In long overhang machining, it reduces tool deflection due to insufficient rigidity, ensuring machining accuracy. The 1°–3° micro-tilt structure makes the diameter change between the cutting head and the clamping section gradual. Compared to right angles or large angle transitions, this reduces the stress concentration coefficient in the transition zone, making it less prone to cracking or breakage under high-frequency cutting vibration, thus extending tool life. The slightly larger diameter of the clamping section, smoothly connected through the transition zone, increases the contact area between the tool and the chuck during clamping, enhancing friction, reducing relative sliding during machining, improving clamping stability, and preventing dimensional deviations caused by sliding. The gentle tilt of the transition zone provides a smooth channel for chip removal, preventing chip accumulation in the transition zone. The adjustable diameter ratio and selectable micro-tilt angle allow the tool to be flexibly adjusted according to different machining materials and cutting parameters, enhancing tool versatility.

[0056] In a preferred embodiment of the present invention, step 3 above, which involves importing the tool substrate structure into a finite element analysis model, performing geometric and mechanical correlation analysis, and obtaining the cutting edge structure adjustment parameters based on the analysis results, may include:

[0057] In this embodiment of the invention, step 330 involves importing the tool substrate structure into finite element analysis software, setting material properties, boundary conditions, and cutting load conditions, and performing mechanical simulation on the stress distribution, strain state, and vibration response of the tool during the cutting process to obtain initial simulation results. Specifically, this includes: firstly, importing the three-dimensional geometric model of the tool substrate, such as a model constructed using CAD software, into finite element analysis software such as ANSYS or ABAQUS in a common format like IGES or STEP; preprocessing the three-dimensional geometric model in the software, including checking the integrity of the three-dimensional geometric model, deleting redundant small features such as micro-chamfers and irrelevant hole structures to reduce the amount of computation; and simultaneously meshing the three-dimensional geometric model, adjusting the mesh density according to the importance of different parts of the tool, using smaller high-order elements such as tetrahedral 10-node elements or hexahedral 20-node elements for key areas such as the cutting edge, and using relatively larger elements for other areas of the substrate to ensure that the mesh quality meets the computational accuracy requirements, such as a mesh distortion rate of less than 5% and an element aspect ratio controlled within 1:5. Based on the actual material used in the cutting tool, such as cemented carbide WC-Co or high-speed steel W18Cr4V, consult material mechanical property parameter manuals or obtain key parameters through material testing, and input them one by one into the finite element software. For example, set the elastic modulus of cemented carbide to 600-650 GPa, the Poisson's ratio to 0.22-0.25, and the density to 14.5-15.0 g / cm³. 3Yield strength, such as the yield strength of cemented carbide is set to 2000-2500MPa and the fracture toughness is set to 10-15MPa・m^(1 / 2). For high-temperature cutting scenarios, it is also necessary to input material performance parameters at different temperatures, such as the elastic modulus attenuation coefficient at 200℃, 400℃ and 600℃, to ensure that the material properties are consistent with the actual working conditions.

[0058] Based on the tool's installation method on the actual cutting equipment, such as tool holder clamping or flange fixing, constraints are defined in the finite element model. If tool holder clamping is used, the degrees of freedom in the contact area between the tool holder and the fixture are restricted. Typically, translational degrees of freedom in the X, Y, and Z directions and rotational degrees of freedom about the X and Y axes are constrained, while only the rotational degree of freedom about the Z axis is retained to simulate cutting rotation. If flange fixing is used, all degrees of freedom on the flange contact surface are constrained. Simultaneously, environmental boundary conditions are set, such as the ambient temperature during the cutting process, typically set to 25-30℃, and the thermal convection coefficient, which is set according to the cutting fluid used; for dry cutting, the convection coefficient is 5-10 W / (m³). 2 •K), 20-30W / (m) during wet cutting 2 •K), ensuring boundary conditions conform to the actual installation and working environment; determine cutting load parameters through cutting tests or theoretical calculations. First, based on the material being machined, such as 45 steel or aluminum alloy, and the cutting parameters (cutting speed v = 100-300 m / min, feed rate f = 0.1-0.3 mm / r, depth of cut ap = 0.5-5 mm), use empirical formulas, such as Merchant's cutting force formula, to calculate the magnitude of the main cutting force Fc, radial cutting force Fp, and axial cutting force Ff. For example, for cutting 45 steel, when v = 200 m / min and f = 0.2 mm / r, the cutting load parameters are: cutting speed v = 100-300 m / min, feed rate f = 0.1-0.3 mm / r, depth of cut ap = 0.5-5 mm. When / r and ap=2mm, Fc is approximately 1500-2000N, Fp is approximately 800-1200N, and Ff is approximately 500-800N. The calculated cutting forces are applied to the finite element model according to the actual application position, such as the tool tip area where the cutting edge contacts the workpiece. At the same time, the dynamic fluctuation characteristics of the cutting force are considered. By adding a sinusoidal fluctuation load, the fluctuation frequency is calculated based on the spindle speed. For example, when the spindle speed n=3000r / min, the fluctuation frequency is 50Hz, and the fluctuation amplitude is 10%-20% of the average cutting force, simulating the dynamic load situation in actual cutting.

[0059] After completing the above settings, select a suitable finite element solver, such as a static solver for stress-strain analysis, and a modal solver and transient dynamics solver for vibration response analysis. In stress-strain analysis, a general static solution method is used, and convergence criteria are set, such as force convergence error less than 1e-5 and displacement convergence error less than 1e-6. The three-dimensional stress distribution cloud map of the tool under cutting load is obtained, including normal stress, shear stress, and strain distribution cloud maps. In vibration response analysis, the first 10 natural frequencies and mode shapes of the tool are calculated first using the modal solver. For example, the first natural frequency is usually 500-1000Hz. Then, the transient dynamics solver is used with the set dynamic cutting load as excitation to solve the displacement response, velocity response, and acceleration response of the tool at different times, such as 0-0.1s, with a time step of 0.001s. Finally, the data such as stress distribution, strain state, vibration response, and displacement, velocity, and acceleration curves over time are integrated to form the initial simulation results.

[0060] Step 331: Based on the initial simulation results, extract equivalent stress distribution, cutting force fluctuation, and mode shape characteristic data; identify stress concentration areas and vibration-sensitive parts; and correlate and locate them to the corresponding cutting edge geometry to obtain the correlation and location results. Specifically, this includes: using the data extraction function of finite element software from the stress distribution cloud map of the initial simulation results, selecting all elements in and around the tool cutting edge (usually extending 2-5 mm from the cutting edge into the matrix) as the analysis object; calculating the equivalent stress of each element; and using the software's statistical function to obtain the maximum, minimum, average, and standard deviation of the equivalent stress in this area. Simultaneously, generate an equivalent stress contour map, marking areas where the equivalent stress exceeds 80% of the material's yield strength, and determining... For high-stress regions, force sensor simulation data at the point of application of cutting force are extracted from transient dynamic simulation results to obtain the original curves of the main cutting force Fc, radial cutting force Fp, and axial cutting force Ff as a function of time. The original curves are preprocessed using the moving average method with a window size of 5-10 time steps to eliminate high-frequency noise. The time-domain signal is then converted into a frequency-domain signal using Fourier transform to obtain the frequency spectrum of the cutting force. The main frequency components of the cutting force fluctuation are identified, such as the fundamental frequency related to the spindle speed, the harmonic frequency related to the number of tool teeth, and the amplitude of each frequency component. The fluctuation coefficient of the cutting force is calculated (fluctuation coefficient = (maximum value - minimum value) / average value, usually requiring the fluctuation coefficient to be less than 0.3).

[0061] From the modal simulation results, the first 5 key vibration modes of the tool are extracted. The displacement data of the vibration modes with natural frequencies close to the main fluctuation frequency of the cutting force are selected, including the amplitude values ​​of each node in the X, Y, and Z directions. The vibration mode of the tool is observed through the vibration mode animation function of the software to determine the area with the largest vibration displacement, such as the tool tip and the middle section of the cutting edge. The maximum amplitude of the cutting edge of the tool under each vibration mode is calculated. Usually, the amplitude at the tool tip is used as a reference. If the amplitude exceeds 10μm, it is determined to be a vibration sensitive area. At the same time, the natural frequency and damping ratio of each vibration mode are recorded. The damping ratio is usually set to 0.01-0.05 through the attenuation characteristics of the transient response curve. The extracted high-stress area data and vibration-sensitive area data are correlated with the tool's three-dimensional geometric model. First, a mapping relationship between the geometric model and simulation results is established in the finite element software. By using node numbering or coordinate matching, the geometric location corresponding to the high-stress area is determined, such as the tool tip fillet or the transition between the cutting edge and the tool holder. The geometric coordinates of this location and the corresponding cutting edge number are recorded, such as main cutting edge 1 and secondary cutting edge 2. For vibration-sensitive areas, coordinate matching is also used to determine the cutting edge geometry corresponding to the part with the maximum vibration displacement, such as the middle section of the main cutting edge or the tip of the secondary cutting edge. The geometric features of this part are marked, such as the edge sharpness and the cutting edge inclination angle. Finally, a correlation and positioning report is generated, which clarifies the specific cutting edge and geometric location corresponding to each stress concentration area and vibration-sensitive part, providing a positioning basis for parameter adjustment.

[0062] Step 332: Based on the correlation positioning results, analyze the main causes of stress concentration and vibration sensitivity, and determine the types and value ranges of geometric parameters that need to be adjusted for each cutting edge. These geometric parameters include the rake angle, clearance angle, and inclination angle. Specifically, based on the correlation positioning results and combined with tool geometry and mechanical simulation data, analyze the main causes of stress concentration. If the stress concentration is located at the tool tip fillet, compare the stress distribution under different fillet radii, such as simulating the stress conditions at fillet radii r = 0.1 mm, 0.2 mm, and 0.3 mm respectively. It is found that the smaller the fillet radius, the more obvious the stress concentration at the tool tip. For example, r = 0.1 mm... When the stress concentration is 30%-50% higher than when the r=0.3mm, the cause is determined to be excessive geometric curvature of the tool tip leading to stress concentration. If the stress concentration is located at the transition between the cutting edge and the tool holder, by checking the geometry of the transition area, it is found that the transition radius is too small, such as the transition radius R=1mm, which causes a sudden stress change during load transfer. The cause is determined to be unreasonable geometric structure of the transition area. At the same time, combined with material properties and load distribution, it is analyzed whether there is excessive local load, such as uneven distribution of cutting force in a certain section of the cutting edge, causing the stress in that area to exceed that in other areas by more than 20%. The core cause of stress concentration is determined by comprehensive analysis.

[0063] For vibration-sensitive areas, the main causes of vibration sensitivity are analyzed by combining mode shape characteristics and cutting load frequency. If the natural frequency of the vibration-sensitive area is close to the main fluctuation frequency of the cutting force (e.g., the natural frequency is 50Hz and the fundamental frequency of the cutting force fluctuation is 48Hz, with a frequency difference of less than 5%), the cause is determined to be resonance amplification. If the vibration-sensitive area is located in a slender region of the tool cutting edge, such as a slender cutting edge with a length-to-diameter ratio greater than 10, the stiffness of this region is calculated (stiffness k=EI / L). 3 (where E is the elastic modulus, I is the moment of inertia of the section, and L is the cutting edge length). It was found that the stiffness value was lower than that of other areas. For example, the stiffness of the slender cutting edge was 1000 N / mm, while that of other areas was 3000 N / mm. The cause was determined to be insufficient stiffness of the cutting edge structure, which makes it susceptible to vibration caused by dynamic loads. In addition, it is necessary to analyze the fluctuation range of the cutting force. For example, if the fluctuation range exceeds 20% of the average cutting force, it may be too large, leading to an enhanced vibration response of the tool. The core cause of vibration sensitivity was determined by comprehensive analysis.

[0064] Based on the causes of stress concentration and vibration sensitivity, the types of geometric parameters that need to be adjusted are determined. If stress concentration is caused by an excessively small tool tip radius or an unreasonable transition area, and vibration sensitivity is caused by insufficient cutting edge stiffness, considering the influence of tool geometry parameters on mechanical properties, the rake angle affects the magnitude of cutting force and stress distribution, the clearance angle affects cutting edge strength and heat dissipation, and the inclination angle affects the direction of cutting force and vibration pattern. Therefore, the adjustment parameters are determined to be the rake angle, clearance angle, and inclination angle. For example, increasing the rake angle can reduce the cutting force, thereby reducing stress concentration; increasing the clearance angle can improve heat dissipation, but cutting edge strength must be guaranteed; adjusting the inclination angle can change the distribution of cutting force on the cutting edge, reducing load concentration in vibration-sensitive areas. Based on tool design specifications, material properties, and preliminary simulation data, the value ranges of each geometric parameter were determined. For the rake angle, referencing similar tool design experience, such as the typical rake angle of carbide tools for machining steel (-5°-15°), and considering the influence of the rake angle on cutting force and stress in the initial simulation, for example, with a current rake angle of 5°, the simulation showed a cutting force of 1800N and a stress concentration of 2200MPa; if the rake angle increased to 10°, the cutting force could be reduced to 1600N and the stress concentration to 2000MPa. However, when the rake angle exceeded 15°, the cutting edge strength would decrease, and the cutting edge stress would exceed the material strength. Based on 90% of the yield strength, the rake angle is determined to be within the range of 5°-15°. For the clearance angle, considering both cutting edge strength and heat dissipation requirements, the current clearance angle is 8°. Simulations show good heat dissipation, but only moderate strength. Increasing the clearance angle to 12° improves heat dissipation by 10%, but reduces cutting edge strength by 8%. Decreasing the clearance angle to 5° increases strength by 12%, but reduces heat dissipation by 15%. Combining this with the material's yield strength, the clearance angle is determined to be within the range of 5°-12°. For the rake angle, based on vibration response simulation results, the current rake angle is 0°, and the tool tip amplitude is 0.015mm. When the rake angle is adjusted to -5°, the amplitude decreases to 0.01mm. When the rake angle is adjusted to 5°, the amplitude decreases to 0.012mm. However, when the rake angle exceeds ±10°, the cutting force distribution becomes abnormal. Therefore, the rake angle is determined to be within the range of -10°-5°.

[0065] Step 333: Within the determined range of values, perform multiple sets of parametric simulations using the finite element model for comparison, and select a set of parameter values ​​that result in more uniform stress distribution and reduced vibration amplitude as the final determined adjustment parameters for the cutting edge structure. Specifically, within the determined range of rake angle (5°-15°), clearance angle (5°-12°), and cutting edge inclination angle (-10°-5°), adopt an orthogonal experimental design method to reduce the number of simulation experiments and ensure parameter coverage, based on the orthogonal table L9 (3 3(3 parameters, 3 levels for each parameter) Design 9 sets of parameter combination schemes, for example, Scheme 1 (5° front angle, 5° back angle, -10° edge inclination), Scheme 2 (5° front angle, 8° back angle, -5° edge inclination), Scheme 3 (5° front angle, 12° back angle, 0° edge inclination), Scheme 4 (10° front angle, 5° back angle, -5° edge inclination), Scheme 5 (10° front angle, 8° back angle, 0° edge inclination), Scheme 6 (10° front angle, 12° back angle, 5° edge inclination), Scheme 7 (15° front angle, 5° back angle, 0° edge inclination), Scheme 8 (15° front angle, 8° back angle, 5° edge inclination), Scheme 9 (15° front angle, 12° back angle, -10° edge inclination). Ensure that the parameter combination of each scheme is evenly distributed within the value range and covers the key levels of each parameter.

[0066] For each set of parameter combinations, the geometric parameters of the tool model, such as the rake angle, clearance angle, and cutting edge inclination angle, are automatically adjusted using the parametric modeling function in the finite element software. For example, parameter adjustment can be achieved by modifying the cross-sectional angle of the tool cutting edge and the cutting edge curve equation, without having to rebuild the entire model. The material properties, boundary conditions, and cutting load conditions are kept consistent with step 330 to ensure the uniformity of simulation conditions. Stress-strain simulation and vibration response simulation are performed on the nine sets of schemes in sequence. The key simulation results of each set of schemes are recorded, including the maximum value, average value, and standard deviation of the equivalent stress at the cutting edge, which reflects the uniformity of stress distribution. The smaller the standard deviation, the more uniform the stress distribution. The maximum amplitude at the tool tip is also recorded. The smaller the amplitude, the better the vibration control effect. At the same time, the cutting force of each set of schemes is recorded to ensure that the adjusted cutting force is within a reasonable range and does not exceed the equipment's load-bearing capacity.

[0067] A multi-index evaluation system was established to quantitatively score the simulation results of nine schemes. Weights were assigned as follows: stress distribution uniformity (standard deviation) 40%, vibration amplitude (tool tip amplitude) 40%, and cutting force magnitude 20%. According to the scoring criteria, for example, stress standard deviation ≤ 50 MPa received 40 points, 50-100 MPa 30 points, 100-150 MPa 20 points, and > 150 MPa 10 points; tool tip amplitude ≤ 10 μm received 40 points, 10-15 μm 30 points, 15-20 μm 20 points, and > 20 μm 10 points; cutting force ≤ 1600 N received 20 points, 1600-1800 N 15 points, and 1800-2000 N 10 points. >2000N gets 5 points. Calculate the comprehensive score for each scheme. For example, the simulation results of scheme 5 (rake angle 10°, clearance angle 8°, cutting edge inclination angle 0°) are: stress standard deviation 45MPa (40 points), tool tip amplitude 0.009mm (40 points), cutting force 1550N (20 points), and comprehensive score 100 points. Other schemes such as scheme 2 have a comprehensive score of 85 points and scheme 6 has a comprehensive score of 90 points. Scheme 5 has the highest score. At the same time, verify whether the parameters of scheme 5 meet other requirements of tool design, such as whether the cutting edge strength is sufficient and whether the machining accuracy meets the standards. After confirming that there are no problems, the parameters of scheme 5 (rake angle 10°, clearance angle 8°, cutting edge inclination angle 0°) are used as the final determined cutting edge structure adjustment parameters.

[0068] By using refined mesh generation, computational accuracy is ensured while reducing computational load, avoiding simulation errors caused by poor mesh quality. Precise setting of material properties, boundary conditions, and cutting loads ensures the simulation model closely matches actual cutting conditions, guaranteeing that initial simulation results accurately reflect the tool's mechanical behavior. Simultaneously, stress-strain and vibration response analyses are performed, acquiring multi-dimensional data such as stress distribution, strain state, and vibration displacement / velocity / acceleration during the cutting process in a single operation, eliminating the need for multiple simulations and improving analysis efficiency. Modal analysis yields natural frequencies and mode shapes, providing key parameters for subsequent vibration sensitivity analysis and preventing the omission of important mechanical properties. Finite element simulation replaces some physical cutting tests, eliminating the need to fabricate multiple tool samples, reducing material consumption and equipment usage time, and lowering R&D costs.

[0069] In a preferred embodiment of the present invention, step 4 above, which involves designing the main cutting edge as a helical edge structure in the finite element analysis model based on the cutting edge structure adjustment parameters, determining the helical angle value by combining the tool diameter and cutting conditions, and adjusting the cutting edge geometry based on the finite element simulation results to generate the helical cutting edge structure, may include:

[0070] In this embodiment of the invention, step 440 involves setting the initial spatial orientation parameters of each main cutting edge in the finite element model based on the spatial posture requirements of each cutting edge determined by the cutting edge structure adjustment parameters. Specifically, this includes: retrieving the determined cutting edge structure adjustment parameters, assuming these parameters are a rake angle of 10°, a clearance angle of 8°, and a cutting edge inclination angle of -5°. These three parameters determine the spatial posture of the main cutting edge from the three dimensions of radial cutting angle, cutting edge clearance angle, and spatial torsion angle, respectively, and are the core basis for setting subsequent orientation parameters; retrieving the constructed three-dimensional model of the tool base from the model database of the finite element analysis software, using the tool rotation center axis, i.e., the central axis when the tool rotates, as the Z-axis, and the center of the end face of the tool holder near the cutting edge as the origin (0, 0, 0), establishing a right-handed Cartesian spatial coordinate system. The X-axis points horizontally outward from the tool, the Y-axis is perpendicular to the X-axis and on the horizontal plane, and the Z-axis points along the tool axis towards the cutting edge, forming a reference coordinate system for spatial orientation calculation.

[0071] Based on the number of cutting edges designed for this tool, it is a six-flute tool, commonly found in milling cutters and drills. The initial circumferential orientation of each primary cutting edge is calculated. Since a six-flute tool needs to evenly bear the cutting load, the six primary cutting edges in the XY plane, perpendicular to the Z-axis, need to be evenly distributed circumferentially. The circumferential angle is 360° ÷ 6 = 60°. Therefore, the initial circumferential angle of the first primary cutting edge is set to 0°, meaning the cutting edge starts in the positive X-axis direction. The second is 0° + 60° = 60°, the third is 60° + 60° = 120°, and so on up to 300°. The initial circumferential position of each primary cutting edge on the horizontal plane is determined through angle allocation. The rake angle parameter is set to the tilt angle within the radial section. The radial section is a section perpendicular to the Z-axis, such as the end face section of the tool. Using the radial radius line of the tool within this section as the reference line, the cutting plane of the main cutting edge, the plane that contacts the chips during cutting, is rotated 10° away from the workpiece around the edge line of the main cutting edge. This is the rake angle value. This ensures that the chips can be smoothly discharged along the cutting plane during cutting, while maintaining the sharpness of the cutting edge. During the adjustment process, the angle between the cutting plane and the reference line is monitored in real time using the angle measurement tool in the software until it is accurately set to 10°, thus completing the radial tilt angle setting.

[0072] Based on the clearance angle parameter, set the inclination angle within the axial section. The axial section is a section parallel to the Z-axis, such as the longitudinal section of the tool. Using the tool's cylindrical generatrix within this section, parallel to the Z-axis and along the outer circle of the tool, as the reference line, rotate the clearance face of the main cutting edge—the plane that contacts the machined surface of the workpiece during cutting—by 8° around the cutting edge line in a direction away from the machined surface. This is the clearance angle value. This avoids excessive friction between the clearance face and the machined surface of the workpiece. Observe the angle between the clearance face and the reference line using the software's section view function, and repeatedly fine-tune the position of the clearance face until the angle is precisely 8°. This completes the axial inclination angle setting, combined with the cutting edge inclination angle. The parameter setting is the spatial torsion angle. The inclination angle is the angle between the main cutting edge and the horizontal plane (XY plane). -5° indicates that the main cutting edge is torsion in the negative Z-axis direction and the tool holder direction. With the tool axis (Z-axis) as the center axis of torsion, the main cutting edge, whose radial and axial inclination angles have been set, is rotated 5° clockwise around the Z-axis. Since the inclination angle is negative, the rotation direction is opposite to the positive angle. During the rotation, the spatial coordinate measurement function of the software is used to monitor the change of the Z-axis coordinate of the midpoint of the cutting edge. If the starting coordinate of the cutting edge is (R, 0, 0) (R is the tool radius, assumed to be 10mm, i.e., the starting coordinate is (10, 0, 0)), after rotating 5°, the coordinate of the midpoint of the cutting edge (at Z=15mm) becomes (10cos (-5°), 10sin (-5°), 15)≈(9.96, -0.87, 15). The accuracy of the torsion angle is verified by the coordinates to ensure that the inclination angle is exactly -5°.

[0073] By integrating the aforementioned circumferential angle, radial tilt angle, axial tilt angle, and spatial torsion angle, complete initial spatial orientation parameters for each main cutting edge are formed, including the coordinates of the starting point, midpoint, and ending point of the cutting edge. Assuming the effective length of the cutting edge is 30mm and the Z-coordinate of the ending point is 30mm, as well as the spatial angle parameters of the cutting plane and the flank face, these parameters are marked and saved in the finite element software to provide a precise initial orientation reference for the subsequent construction of the helical cutting edge structure.

[0074] Step 441: Based on the initial spatial orientation parameters, combined with the total tool diameter and preset cutting conditions, calculate and select the specific value of the helix angle within the range of 30° to 45°. Construct each main cutting edge into a helical edge structure with a constant helix angle according to the specific value. Specifically, this includes: first obtaining the total tool diameter parameter, for example, if the total tool diameter is 20mm, calculating the tool radius (radius = diameter / 2 = 10mm) from the diameter. This radius value is the key geometric reference for calculating the helix angle. Clarify the preset cutting conditions, including the hardness of the workpiece material (e.g., HB220 for 45 steel), cutting speed (e.g., 200m / min), and feed rate (e.g., 0.2mm / r). If the workpiece material has a high hardness (e.g., HB > 250) or a high cutting speed (e.g., > 250m / min), a larger helix angle needs to be selected to improve chip removal efficiency; if the feed rate is large (e.g., > 0.3mm / r), a smaller helix angle needs to be selected to ensure the edge strength.

[0075] Based on the above parameters, the helix angle is calculated within the range of 30°-45°. First, based on the tool radius and cutting edge length, such as an effective cutting edge length of 30mm, the lead range of the helix is ​​calculated. Lead = (tool circumference) / tan (helix angle). Tool circumference = π × diameter = π × 20mm ≈ 62.8mm. When the helix angle is 30°, tan (30°) ≈ 0.577, and lead ≈ 62.8 / 0.577 ≈ 108.8mm. When the helix angle is 45°, tan (45°) = 1, and lead ≈ 62.8 / 1 = 62.8mm. Considering the cutting conditions, if machining 45 steel (hardness HB220), cutting speed 200m / min, and feed rate 0.2mm / r, a balance between chip removal and strength needs to be achieved. A lead of approximately 80mm is selected. The helix angle is then calculated by back-calculating the lead. (Helix angle) = tool circumference / lead ≈ 62.8 / 80 ≈ 0.785, corresponding to a helix angle of about 38°. Finally, 38° was selected as the specific helix angle value within the range of 30°-45°.

[0076] Based on a helical angle of 38°, the helical cutting edge structure is constructed. Using the initial spatial orientation parameters of the main cutting edge set in step 440 as a basis, and with the tool axis (Z-axis) as the helical centerline, the cutting edge of the main cutting edge is spirally raised along the Z-axis according to the calculated lead (80mm). For example, if the starting point coordinates of the cutting edge are (10, 0, 0), for every 1mm increase along the Z-axis, it rotates clockwise in the XY plane by (360° / lead) × 1mm = (360 / 80) × 1 = 4.5°. Therefore, the coordinates of the midpoint of the cutting edge (at Z=15mm) are (10cos(-4.5°×15), 10sin(-4.5°×15), 15) ≈ (10cos(-67.5°), 10sin(-67.5°), 15) ≈ (3.83, -9.24, 15), and the coordinates of the ending point of the cutting edge (at Z=30mm) are (10cos(-67.5°), 10sin(-67.5°), 15) ≈ (3.83, -9.24, 15). (-135°), 10sin (-135°), 30)≈(-7.07, -7.07, 30). By calculating the coordinates in this way, each main cutting edge is constructed as a helical edge structure with a constant helical angle of 38°, and the corresponding helical edge geometry is generated in the finite element model.

[0077] Step 442: Based on the geometric characteristics of the helical cutting edge structure, calculate and determine the matching cutting edge width parameters. Specifically, this includes: First, analyzing the geometric characteristics of the helical cutting edge structure, including the helix angle (38°), tool radius (10mm), rake angle (10°), and clearance angle (8°). These parameters together determine the range of the cutting edge width. The cutting edge width must match the helix angle of the helical cutting edge to avoid excessive width leading to increased friction, or insufficient cutting edge strength due to excessive narrowness. Referring to the tool design industry standards, for helical cutting edge tools, the cutting edge width is usually 5%-10% of the tool radius. Considering the tool radius of 10mm, the initial range of the cutting edge width is determined to be 0.5mm-1mm. Then, this range is corrected according to the helix angle. The larger the helix angle, the smaller the cutting edge width needs to be (to avoid clogging the chip removal channel). 38° is a medium helix angle, and the middle value of 0.75mm can be taken as the initial calculation value within the preliminary range.

[0078] Based on the preset feed rate of 0.2mm / r, the cutting edge width needs to be greater than 1.5 times the feed rate (to ensure that the cutting edge can stably support the cutting edge during cutting). 0.2mm × 1.5 = 0.3mm, and 0.75mm meets this requirement. At the same time, considering the hardness of the workpiece material, 45 steel has moderate hardness, so the cutting edge width does not need to be too large. 0.75mm can balance strength and friction. In the finite element model, the connection between the cutting edge and the helical edge is simulated, and the projected width of the cutting edge in the radial direction (perpendicular to the Z-axis) and axial direction (parallel to the Z-axis) is calculated. Radial projected width = cutting edge width × cos (helix angle) = 0.75mm × cos (38°) ≈ 0.75 × 0.788 ≈ 0.59mm, and axial projected width = cutting edge width × sin (helix angle) = 0.75 × 0.616 ≈ 0.46mm. It is confirmed that this projected width will not cause geometric interference with other tool structures (such as tool holder, chip flute). Finally, the cutting edge width parameter is determined to be 0.75mm.

[0079] Step 443: Substitute the helical cutting edge structure and cutting edge width parameters into the finite element model for cutting simulation. Based on the cutting force, stress distribution, and chip removal characteristics data obtained from the simulation, modify the local geometry of the rake face and flank face. Specifically, import the helical cutting edge structure (38° helix angle) constructed in step 441 and the cutting edge width (0.75mm) determined in step 442 into the finite element model, maintaining the same material properties as in step 330, such as the cemented carbide elastic modulus of 630GPa, Poisson's ratio of 0.23, boundary conditions, tool holder clamping constraints, ambient temperature of 25℃, and cutting load conditions, with the main cutting force of 1550N, radial force of 750N, axial force of 550N, and dynamic fluctuation frequency of 50Hz, and start the cutting simulation.

[0080] After the simulation is completed, key data are extracted. First, cutting force data: real-time variation curves of main cutting force, radial force, and axial force during the cutting process are obtained through the virtual force sensor preset in the finite element model. The cutting force fluctuation coefficient is calculated (fluctuation coefficient = (maximum value - minimum value) / average value). If the fluctuation coefficient is >0.3 (e.g., 0.35 is calculated), it indicates that the cutting force is unstable. Second, stress distribution data: equivalent stress cloud map of the helical edge and cutting edge area is extracted, and stress concentration areas are marked. For example, the stress near the cutting edge of the rake face reaches 2300MPa, which exceeds 10% of the material yield strength of 2000MPa. Third, chip removal characteristic data: the chip removal speed is observed through the movement trajectory of the chips in the simulation. If the chip removal speed is <50% of the cutting speed and the chip removal direction is not specified, the chips will adhere to the rake face, causing blockage of the chip removal channel.

[0081] Based on the above data, the local geometry of the rake face is corrected. To address poor chip removal and stress concentration on the rake face, the inclination angle of the local area of ​​the rake face near the cutting edge is increased by 2° within 5mm of the cutting edge, from the original 10° to 12°. Specifically, in the finite element model, each coordinate point in this area of ​​the rake face is offset outward by 0.1mm in a direction perpendicular to the cutting plane. By calculating the relationship between the offset and the angle, the offset = distance from the cutting edge × tan (2°). For example, the offset at a distance of 3mm from the cutting edge = 3 × 0.0349 ≈ 0.105mm, thereby expanding the chip removal channel and dispersing stress.

[0082] To correct the local geometry of the flank face, which is prone to excessive friction between the flank face and the workpiece surface, the simulation data on the temperature rise of the flank face was used. If the flank face temperature reached 300℃, which is higher than the normal range of 250℃, the clearance angle of the local area of ​​the flank face near the cutting edge was increased by 1° in the first 3mm of the cutting edge, from the original 8° to 9°. In the finite element model, the coordinate points of this area of ​​the flank face were offset by 0.05mm away from the workpiece surface (offset = distance from the cutting edge × tan(1°), for example, the offset at 2mm from the cutting edge = 2 × 0.01745 ≈ 0.035mm). This reduced the friction area. After the correction, the cutting simulation was performed again until the cutting force fluctuation coefficient was ≤0.3 (e.g., eventually reduced to 0.25), the stress in the stress concentration area was ≤2000MPa, and the chip removal speed was increased to more than 60% of the cutting speed. This completed the local geometry correction.

[0083] Step 444: Based on the corrected geometry and cutting edge parameters, generate the final helical cutting edge structure that meets the requirements for continuous and smooth cutting. Specifically, this includes: First, integrating the local geometric data of the rake face and flank face corrected in step 443. The rake angle of the rake face is 12° within 5mm of the cutting edge, and 10° in the remaining area; the clearance angle of the flank face is 9° within 3mm of the cutting edge, and 8° in the remaining area. At the same time, confirm that the helix angle of the helical cutting edge is still 38°, the cutting edge width is still 0.75mm, and there are no geometric parameter conflicts. In the finite element model, regenerate the complete three-dimensional model of the tool cutting edge based on the corrected geometric parameters. First, update the helical coordinates of each main cutting edge. Based on the corrected rake face and flank face angles, fine-tune the spatial position of the cutting edge line to ensure a smooth connection between the cutting edge and the rake and flank faces. Then, generate the geometry of the cutting edge. The cutting edge extends along the helical direction of the helical cutting edge, with a width of 0.75mm, and smoothly transitions with the corrected flank face, while ensuring that the cylindricity error of the cutting edge is ≤0.01mm.

[0084] The generated cutting edge model was tested for continuous and stable cutting performance. Ten workpiece rotation cycles were simulated in the finite element model. Based on a spindle speed of 3000 r / min, the calculated cycle was 60 / 3000 = 0.02 s, and 10 cycles totaled 0.2 s. Cutting force, stress distribution, and chip removal data were extracted for each cycle. The cutting force fluctuation coefficient was verified to be stable below 0.25, the stress distribution uniform, the maximum stress ≤ 1900 MPa, and chip removal continuous and unobstructed, confirming that the continuous and stable cutting requirements were met. Finally, the verified cutting edge model was assembled with the tool base model to ensure seamless connection between the helical cutting edge structure and other structures such as the tool holder and chip removal groove. The final three-dimensional model of the helical cutting edge structure was generated, and the geometric data of the model was exported for subsequent tool manufacturing, completing the final helical cutting edge structure generation.

[0085] The initial spatial orientation is set based on the pre-determined cutting edge structure adjustment parameters to avoid discrepancies between the subsequent helical cutting edge structure and the design target due to deviations in the orientation parameters. This provides a benchmark for the precise construction of the helical cutting edge, reducing subsequent rework and adjustment costs. By establishing a three-dimensional coordinate system and marking the spatial coordinate points of each cutting edge, the orientation parameters of the cutting edge can be quantified and traced, avoiding subjective errors in traditional manual modeling. This ensures that the finite element model can accurately reflect the spatial posture of the cutting edge. Through lead calculation and coordinate point positioning, the construction process of the helical cutting edge structure is quantified, ensuring that the helix angles of each main cutting edge of the multi-blade tool are consistent and the spatial distribution is uniform. This avoids tool vibration or uneven wear caused by uneven force on each edge, improving the cutting stability and service life of the tool.

[0086] In a preferred embodiment of the present invention, step 5 above, which involves simulating the cutting process by placing the helical cutting edge structure in a finite element analysis model, arranging staggered chip breaker grooves on the cutting edge surface according to the simulation results, and coordinating the distribution shape and contour dimensions to form a cutting edge structure with chip breaker grooves, may include:

[0087] In this embodiment of the invention, step 550 involves importing the helical cutting edge structure into a finite element analysis model, simulating the initial cutting process by setting cutting parameters, and obtaining initial simulation data including chip morphology, cutting force, and stress distribution. Specifically, this includes importing the three-dimensional geometric model of the helical cutting edge into the finite element analysis software in STL or STEP format, checking for defects on the model surface before importing, and ensuring that the dimensional accuracy of the model is controlled within ±0.01mm. If any part exceeds the error range, it needs to be corrected by returning to the modeling software. When setting cutting parameters, first determine the material to be processed. Taking 45 steel as an example, its tensile strength is 600MPa. Based on this characteristic, the initial cutting speed is set to 200m / min. If the material hardness increases, such as reaching 30HRC (the original hardness is 20HRC), the cutting speed is reduced by 20m / min and adjusted to 180m / min. If the hardness decreases, the cutting speed is increased accordingly. The feed rate is determined according to the cutting edge diameter. When the cutting edge diameter is 10mm, the feed rate is set to 0.1mm / r. For every 5mm increase in diameter, the feed rate is increased by 0.05mm / r. For example, when the diameter is 15mm, the feed rate is 0.15mm / r. The cutting depth is taken as 1 / 3-1 / 2 of the cutting edge width. If the cutting edge width is 6mm, the cutting depth range is 2-3mm. The intermediate value of 2.5mm is preferred for the first simulation.

[0088] When defining material properties, the density of the workpiece material, 45 steel, is set to 7.85 g / cm³. 3 The elastic modulus is 206 GPa and Poisson's ratio is 0.3. Input the plastic constitutive equation parameters for the material, including yield strength and strain hardening coefficient. If the tool material is cemented carbide, set its hardness to 90 HRA and thermal conductivity to 80 W / (m·K), and input its fracture toughness and other parameters. When meshing, first determine the cutting edge region of the cutting edge. Use a fine mesh of 0.05 mm for this region and a coarse mesh of 0.2 mm for other regions. After meshing, check the mesh quality to ensure that the mesh distortion does not exceed 15°, thus ensuring the calculation accuracy of the stress concentration zone.

[0089] The simulation ran for three cutting cycles, each corresponding to one revolution of the tool. During the simulation, changes in chip morphology were recorded in real time, with a chip image captured every 0.005 seconds. The curl radius, length, and thickness of the chip were measured and recorded. For example, at 0.01 seconds in the first cycle, the chip curl radius was 3mm, the length was 8mm, and the thickness was 0.15mm; at 0.02 seconds, the curl radius changed to 4mm, the length to 10mm, and the thickness to 0.16mm, etc. When collecting cutting force data, the main cutting force, feed resistance, and back force were calculated from the nodal forces on the tool-workpiece contact surface. Data was recorded every 0.001 seconds, resulting in multiple data points within a single cutting cycle. For example, the main cutting force was 1200N at 0.001 seconds and 1250N at 0.002 seconds, etc. Finally, the average value of all data within each cycle was taken as the cutting force value for that cycle. When analyzing stress distribution, the Von value on the cutting edge surface was extracted. Mises stress values ​​determine the coordinates of the point of maximum stress and the stress gradient. For example, if the maximum stress point is found 2 mm from the cutting edge tip with a stress value of 950 MPa, the stress values ​​within a 5 mm radius around this point are measured sequentially as 900 MPa, 850 MPa, etc., accurate to 1 MPa.

[0090] Step 551: Based on the chip morphology and stress distribution characteristics in the initial simulation data, determine the staggered distribution pattern, initial spacing, and basic outline dimensions of the chip breaker grooves to obtain the initial design parameters of the chip breaker grooves. Specifically, this includes: measuring the average curl radius of the chips in the initial simulation, adding the curl radii at multiple time points and dividing by the number of measurements to obtain the average curl radius O. If the calculated O = 6 mm, which is greater than 5 mm, it indicates that the chip breaking effect needs to be enhanced; if O = 1.5 mm, which is less than 2 mm, it indicates that the chip breaker groove strength needs to be reduced. Calculate the average length D of the chips, and similarly add the chip lengths at multiple time points and divide by the number of measurements. If the calculated D = 10 mm, then the initial spacing of the chip breaker grooves is set between 8 and 12 mm. 10 mm is selected as the initial spacing.

[0091] In stress concentration areas, i.e., areas with stress values ​​> 800 MPa, measure the area and distribution range of these areas. For example, if the area of ​​such an area is 5 mm²... 2The chip breaker grooves are distributed within a 3mm radius of the cutting edge. The depth of the grooves is designed to be 0.3-0.5mm, which is 0.1-0.2mm deeper than the depth of the non-stress concentration zone (stress value ≤800MPa) (0.2-0.3mm). The stress gradient direction is determined, i.e., the direction in which the stress value decreases the most. This is calculated by measuring the stress difference and distance between two adjacent points. For example, if the stress value at two points 1mm apart drops from 900MPa to 700MPa in a certain direction, the gradient is 200MPa / mm, which is the direction of the maximum gradient. Based on this direction, the stagger angle of the chip breaker grooves is determined to be 30°-60° with the spiral line of the cutting edge. The larger this gradient, the better. The smaller the angle, the better; here we take 30°. The staggered distribution pattern uses two rows of staggered arrangement. First, determine the position of the first row of chip-breaking grooves, making its axis parallel to the generatrix of the cutting edge. Measure the direction of the generatrix of the cutting edge to ensure that the parallelism error of the groove axis does not exceed 1°. The center misalignment distance between adjacent rows of grooves is 1 / 2 of the spacing. For example, if the spacing is 10mm, the misalignment distance is 5mm. In the basic outline dimensions, the groove width is set to 1.5-2 times the chip thickness. The average chip thickness is measured to be 0.2mm, so the groove width is 0.3-0.4mm. We first select 0.35mm. The radius of the groove bottom fillet is 1 / 3 of the groove width, that is, 0.35mm ÷ 3 ≈ 0.12mm.

[0092] Step 552: Based on the initial design parameters of the chip breaker groove, construct an initial geometric model of the chip breaker groove on the surface of the spiral cutting edge, and update the geometric model to the finite element analysis environment. Specifically, this includes: in CAD software, drawing a two-dimensional cross-section of the chip breaker groove according to the initial design parameters. First, draw a rectangle with a groove width of 0.35mm and a depth of 0.4mm. Then, round the two right angles at the bottom of the groove to 0.12mm. After drawing, sweep along the spiral surface of the cutting edge to generate a three-dimensional structure. During the sweeping process, ensure the fit between the cross-section and the spiral surface. Check the fit error every 1mm length. The error should not exceed 0.02mm. Check the transition fillet between the chip breaker groove and the cutting edge surface. Use the software measurement tool to measure the radius of the transition fillet and ensure that it is ≥0.05mm. If it is less than this value, re-round the fillet to meet the requirements to avoid stress concentration.

[0093] Export the cutting edge model with the initial chip breaker groove to a format compatible with the finite element software. After importing, assemble it with the workpiece model. Use the software's alignment function to align the cutting edge of the tool with the surface to be cut on the workpiece. Measure the alignment error to ensure it is ≤0.02mm. If the error exceeds this, readjust the assembly position and re-mesh. When re-meshing, use an ultra-fine 0.03mm mesh in the chip breaker groove area. After meshing, check the quantity and quality of the mesh in this area to ensure that there are at least 5 layers of mesh around each chip breaker groove and that the mesh distortion does not exceed 10% to ensure the accuracy of stress calculation around the groove.

[0094] Step 553: Perform a secondary cutting simulation based on the updated geometric model. Adjust the chip breaking effect and cutting force changes in the secondary simulation data to optimize the chip breaker groove's distribution density, depth, and shape profile, generating design parameters. Specifically, use the same cutting parameters as the first simulation: cutting speed 200 m / min, feed rate 0.15 mm / r, depth of cut 2.5 mm, and run two cutting cycles. During the simulation, focus on recording the chip fracture location, such as fracture at 5 mm from the cutting edge; record the fracture frequency, such as 3 fractures in the first cycle and 2 fractures in the second cycle; and simultaneously record the cutting force fluctuation value, i.e., the difference between the maximum and minimum cutting force, such as a maximum main cutting force of 1300 N and a minimum of 1100 N, with a fluctuation value of 200 N.

[0095] To evaluate the chip breaking effect, the fracture length of the chips was measured in the secondary simulation. If the average fracture length was 18mm, exceeding the process requirement of 15mm, the chip breaking groove distribution density was increased. The original spacing was 10mm, which was reduced by 10%-20%, i.e., adjusted to 8-9mm. 8.5mm was selected for the second simulation verification. If the average chip fracture length was 2mm, which was less than the process requirement of 3mm, indicating excessive breakage, the distribution density was reduced, and the spacing was increased by 10%-20%, from 10mm to 11-12mm. 11mm was selected for verification.

[0096] For cutting force adjustment, calculate the difference between the peak cutting force in the second simulation and the first simulation. If the peak cutting force in the first simulation is 1200N and the peak cutting force in the second simulation is 1400N, the increase is (1400-1200)÷1200≈16.7%, which exceeds 15%. Then reduce the depth of the chip breaker groove by 0.05mm each time, from 0.4mm to 0.35mm. If the peak cutting force after the second simulation is 1300N, the increase is (1300-1200)÷1200≈8.3%, which is ≤10%. Then determine the depth. If the chip breaking effect is not good, such as the chip fracture length is still 16mm and the cutting force does not change much, the increase is 5%. Then adjust the groove profile, increase the groove inclination angle from 30° to 35°-40°, or increase the inclination of the groove bottom so that the depth of the front end of the groove is 0.4mm and the depth of the rear end is 0.3mm, with a shape that is deeper at the front and shallower at the back.

[0097] After 2-3 iterations of adjustment, such as adjusting the spacing to 8.5mm, the depth to 0.35mm, and the angle to 35°, the chip breaking effect and cutting force meet the requirements. At this point, the final chip breaking groove distribution density is determined to be 1-2 grooves per 10mm length, with a depth of 0.35mm and a groove profile tilt angle of 35°, etc. All parameters are accurate to 0.01mm and 1°.

[0098] Step 554: Based on the chip breaker design parameters, generate chip breaker grooves with a distribution pattern and contour size on the surface of the spiral cutting edge, ultimately forming a cutting edge structure with chip breaker grooves. Specifically, this includes: accurately machining and modeling the chip breaker grooves on the surface of the spiral cutting edge according to the final design parameters; using the positioning function of CAD software to determine the position of each chip breaker groove; measuring its deviation from the theoretical position to ensure that the position error is ≤0.03mm; measuring the actual dimensions of the chip breaker grooves, such as groove width and depth, with an error of ≤0.01mm from the design parameters; if the error exceeds the limit, making fine adjustments; checking the coordination between the chip breaker grooves and the spiral angle of the cutting edge; measuring the angle formed by the extension direction of the groove and the rotation direction of the cutting edge to ensure that the deviation is ≤2°; for example, if the spiral angle of the cutting edge is 30°, the angle between the extension direction of the groove and the rotation direction should be 28°-32°.

[0099] Interference checks are performed on the final precision-machined model. The software's interference analysis function is used to check the distances between chip breaker grooves and between the grooves and the edge of the cutting edge, ensuring no overlap or excessive proximity, with a minimum spacing of ≥0.5mm. If the distance between two chip breaker grooves is found to be 0.4mm, the position of one of the grooves needs to be adjusted to achieve a distance of ≥0.5mm. A 3D model of the cutting edge structure with chip breaker grooves is generated and saved in a universal format for subsequent machining. A test report of the 3D model of the cutting edge structure is also output, including data on dimensional accuracy and positional accuracy.

[0100] Detailed data such as chip morphology and stress distribution are obtained through finite element simulation. Based on this, the distribution and size of the chip breaker groove are designed, enabling the chip breaker groove to act precisely on the chip and effectively guide chip breakage. During the secondary simulation, parameters are adjusted in a targeted manner according to the chip breaking effect and changes in cutting force, resulting in more stable cutting force, reduced tool vibration, lower tool wear rate, fewer tool replacements, and improved machining continuity. When designing the chip breaker groove, stress distribution characteristics are fully considered, and the depth and contour of the chip breaker groove are reasonably designed in stress concentration areas to meet chip breaking requirements while avoiding excessive grooving that weakens the strength of the cutting edge structure. For different cutting parameters and material properties, a suitable chip breaker groove design can be quickly obtained by adjusting simulation parameters without redesigning the overall cutting edge structure. Only the distribution density and depth of the chip breaker groove need to be adjusted to make the tool suitable for various machining scenarios, reducing the tool procurement cost for enterprises.

[0101] In a preferred embodiment of the present invention, step 6 above, based on the cutting edge structure with chip breaker grooves, simulates and analyzes the stress distribution and cutting load at the cutting edge using a finite element analysis model, and sets the width and spatial orientation parameters of the cutting edge to complete the comprehensive design of the anti-vibration ball end mill, may include:

[0102] In this embodiment of the invention, step 660 involves importing the cutting edge structure with chip breaker grooves into a finite element analysis model for cutting simulation, obtaining simulation data including the distribution of cutting edge stress and cutting load. Specifically, this includes: first, importing the three-dimensional model of the cutting edge structure with chip breaker grooves, including the depth, width, and spacing of the chip breaker grooves, the initial thickness of the cutting edge, and other geometric features, into finite element analysis software such as ANSYS or ABAQUS; then, using the software's built-in geometric verification tool, checking the key dimensions of the three-dimensional model of the cutting edge structure, such as the bottom fillet radius of the chip breaker grooves and the edge sharpness of the cutting edge, against the design drawings to ensure that the deviation does not exceed 0.01 mm, thereby ensuring the accuracy of the simulation.

[0103] Material properties and boundary conditions are set by assigning physical properties to the cutting tool (e.g., cemented carbide) and the workpiece (e.g., high-strength steel), including elastic modulus (approximately 600-700 GPa for the cutting tool and approximately 200-210 GPa for the workpiece), Poisson's ratio (approximately 0.22-0.25 for the cutting tool and approximately 0.27-0.3 for the workpiece), and density (approximately 14-15 g / cm³ for the cutting tool). 3 The workpiece has a weight of approximately 7.8-7.9 g / cm³. 3 The tool's yield strength (approximately 800-1000 MPa) and cutting boundary conditions are set. Cutting speed is set to 100-300 m / min, with three typical speed gradients. Feed rate is set to 0.05-0.2 mm / r, with five levels. Depth of cut is set to 0.5-2 mm, using three commonly used values. The tool-workpiece contact method is defined as Coulomb friction, with a friction coefficient set to 0.3-0.5, adjusted according to the material properties. Mesh generation and simulation are performed: fine meshing (mesh size 0.01-0.05 mm) is used for stress concentration areas such as the cutting edge and chip breaker groove, while coarser meshing (0.1-0.05 mm) is used for other areas. To balance computational accuracy and efficiency, a simulation time step (e.g., 0.001-0.01s) is set and dynamically adjusted according to the cutting speed. After the simulation starts, the stress changes (e.g., Mises stress) and numerical fluctuations of cutting loads (axial force, radial force, tangential force) at each node of the cutting edge are monitored in real time. After the simulation ends, the cutting edge region is extracted, and the stress value of a monitoring point is taken every 0.1mm along the cutting edge. The maximum stress, average stress, instantaneous value and average value of the three forces during the cutting process are recorded at each point. Data is recorded every 0.01s. Finally, the stable stage data under each working condition is taken to form a simulation dataset containing more than 1000 sets of data.

[0104] Step 661: Based on the stress distribution and load characteristics in the simulation data, analyze the mechanical behavior of the cutting edge under different working conditions, determine the range of the cutting edge width and the direction of spatial orientation adjustment. Specifically, this includes: classifying the stress data obtained in step 660 according to the cutting conditions, drawing the cutting edge stress cloud diagram and stress curve along the cutting edge, statistically analyzing the location of stress concentration areas under different working conditions, such as the junction of the chip breaker groove and the cutting edge, the edge of the cutting edge, and the maximum stress value. Areas exceeding 80% of the tool yield strength are considered high-risk areas. Calculate the stress concentration factor, the ratio of the maximum stress to the average stress. If the ratio exceeds 3, it is determined that the stress concentration is significant. Perform load characteristic analysis, conduct time-domain and frequency-domain analysis on the cutting load data, calculate the peak value of the triaxial force under each working condition. If the peak value of the axial force exceeds 5000N, it is determined that the load is too large and the fluctuation amplitude is too large. Calculate the difference between the peak value and the valley value. If the difference exceeds 30% of the average value, it is considered as load instability and dominant frequency distribution. If the dominant frequency is close to 80%-120% of the tool's natural frequency, there is a risk of resonance. Mechanical behavior and parameter correlation analysis is conducted, comparing stress and load data under different initial cutting edge widths. For example, assuming an initial width of 0.2mm, if stress concentration decreases with increasing width (e.g., a 0.05mm increase in width results in a 10% or greater decrease in maximum stress), then it is preliminarily determined that the cutting edge width needs to be increased. If load fluctuation decreases with increasing cutting edge inclination angle and core parameters of spatial orientation (e.g., an increase in inclination angle from 5° to 10° results in a 15% decrease in fluctuation amplitude), then it is determined that the spatial orientation needs to be adjusted towards increasing the inclination angle. Finally, combining the analysis results, the approximate range of the cutting edge width (e.g., 0.15-0.25mm) and the adjustment direction of the spatial orientation (e.g., the inclination angle needs to be optimized within the range of 5°-15°) are preliminarily determined.

[0105] Step 662: Based on the spatial orientation adjustment direction, generate a set of candidate values ​​for the cutting edge width within the range of 0.1mm to 0.3mm, and combine this with the tool diameter and cutting conditions to form a width parameter scheme. Specifically, this includes: based on the adjustment direction determined in step 661, generating candidate values ​​at uniform intervals within the range of 0.1-0.3mm. If priority testing of the intermediate range is required, generate 11 candidate values ​​at 0.02mm intervals: 0.1mm, 0.12mm, 0.14mm, ..., 0.3mm. If a focused optimization range is required, such as 0.15-0.25mm, then densify the range within this sub-range at 0.01mm intervals, adding 0.155mm, 0.12mm, ..., 0.3mm, ... Eleven additional candidate values, such as 0.165mm, are used to ultimately form 20-25 width candidate values. The width-to-diameter matching relationship is set according to the tool diameter, such as φ5mm, φ10mm, and φ20mm. For small-diameter tools (φ5mm), due to their poor rigidity, the upper limit of the candidate value is set to 0.2mm to avoid excessive width leading to a decrease in rigidity. For medium-diameter tools (φ10mm), 0.15-0.25mm is retained; for large-diameter tools (φ20mm), the range can be relaxed to 0.2-0.3mm. For each diameter model, values ​​that fit the above range are selected from the candidate values. For example, for φ10mm, 0.15, 0.16, ..., 0.25mm are retained, totaling 11 values.

[0106] For different cutting conditions, the candidate values ​​are adjusted as follows: high-speed light-load cutting speed is 250-300 m / min, feed rate is 0.05-0.1 mm / r; low-speed heavy-load cutting speed is 100-150 m / min, feed rate is 0.15-0.2 mm / r. When cutting at high speed and light load, a smaller width, such as 0.15-0.2 mm, is preferred to be retained to reduce cutting resistance; when cutting at low speed and heavy load, a larger width, such as 0.2-0.25 mm, is retained to enhance the cutting edge strength. Finally, a width parameter scheme containing 5-8 candidate values ​​is formed for each combination of tool diameter and cutting conditions.

[0107] Step 663: Substitute the width parameter schemes into the finite element model for simulation comparison. Based on the stress concentration and cutting stability in the comparison results, determine the final cutting edge width value. Specifically, this includes: updating each width parameter scheme formed in step 662 into the cutting edge structure of the finite element model one by one, keeping the chip breaker groove and other parameters unchanged, and repeating the simulation according to the boundary conditions in step 660. For each scheme, record four key indicators: the maximum stress value of the cutting edge, the area of ​​the stress concentration region, the area exceeding the allowable stress of the tool, the cutting force fluctuation coefficient, the ratio of the fluctuation amplitude to the average value, the peak value of the vibration displacement, and the maximum displacement of the cutting edge in the cutting direction. Standardize the scoring of the four indicators, with a maximum score of 10 points. The lower the maximum stress value (e.g., below 60% of the allowable stress of the tool), the more points are awarded; if it exceeds 80%, 0 points are awarded. The smaller the area of ​​the stress concentration region (e.g., less than 0.5 mm), the better. 2 10 points, greater than 2mm 2A score of 0 is awarded for a smaller fluctuation coefficient (e.g., less than 10% earns 10 points, greater than 30% earns 0 points), and a smaller peak vibration displacement (e.g., less than 0.01mm earns 10 points, greater than 0.05mm earns 0 points). Weights are assigned based on the importance of the indicators. Assuming a stress concentration of 40%, cutting force fluctuation of 25%, vibration displacement of 25%, and stress area of ​​10%, the weighted total score for each candidate width is calculated, and the candidate value with the highest total score is selected as the final cutting edge width. If there are multiple high scores with a difference of less than 5%, the value that performs better under heavy load conditions, such as a width with lower stress under low speed and heavy load, is given priority.

[0108] Step 664: Based on the final cutting edge width value, determine the chip flow and heat dissipation characteristics by adjusting the spatial tilt angle of the cutting edge, forming the final spatial orientation parameters. Specifically, this includes: based on the adjustment direction determined in step 661, setting the spatial tilt angle of the cutting edge, and the candidate range of the angle between the cutting edge and the tool axis, such as 5°-15°, generating 11 candidate angles at 1° intervals: 5°, 6°, ..., 15°; substituting the final cutting edge width and each candidate tilt angle combination into the finite element model to simulate the chip formation and discharge path during the cutting process, and recording the chip... The following parameters are considered: curl radius (ideally 5-10 mm), discharge speed (greater than 80% of cutting speed), and contact time with the cutting edge (less than 0.01 s to avoid secondary friction). For each rake angle, the chip flow smoothness score is calculated: 3 points for a curl radius within the ideal range, 3 points for a satisfactory discharge speed, and 4 points for a satisfactory contact time, for a maximum score of 10. Simultaneously, the temperature distribution of the tool edge is recorded, and the average temperature of the cutting edge region is calculated (ideally below 300℃), the maximum temperature (below 400℃), and the heat flux density (less than 50 W / mm²). 2 For each tilt angle, a heat dissipation effect score is calculated. 4 points are awarded for meeting the average temperature target, 3 points for meeting the maximum temperature target, and 3 points for meeting the heat flux density target, for a maximum score of 10 points. The chip flow smoothness score and the heat dissipation effect score are weighted at a ratio of 6:4. Chip flow has a greater impact on cutting stability, so the tilt angle with the highest weighted total score is selected as the final spatial orientation parameter. If the scores are the same, the value with the smaller tilt angle is preferred to reduce the overall size change of the tool.

[0109] Step 665: Apply the final cutting edge width value and spatial orientation parameters to the cutting edge structure to complete the comprehensive design of the anti-vibration ball end mill. Specifically, this includes: inputting the final cutting edge width determined in step 663 (e.g., 0.22mm) and the spatial inclination angle determined in step 664 (e.g., 8°) into the 3D modeling software; updating the cutting edge structure model; ensuring that the parameters are evenly distributed across the entire cutting edge, such as a smooth transition of the cutting edge width along the spherical curvature with a deviation not exceeding 0.01mm; checking the connection dimensions between the cutting edge and the chip breaker groove, such as ensuring the ratio of chip breaker groove depth to cutting edge width is between 1.5 and 2 to avoid stress concentration; ensuring the fillet radius in the transition area between the cutting edge and the tool shank is not less than 0.5mm to enhance overall rigidity; verifying the overall mechanical properties through a finite element model, such as ensuring the tool's overall first-order natural frequency is higher than 2000Hz to avoid resonance; and comparing the design to industry standards for ball end mills, such as ISO. 10911. Confirm that parameters such as the cutting edge width and inclination angle are within the standard allowable range. Control the tolerance of key dimensions, such as the total length of the tool and the ball end radius, within ±0.02mm. Finally, generate design drawings and a bill of materials containing all parameters to complete the comprehensive design.

[0110] Finite element method (FEM) simulation is used to obtain cutting edge stress distribution and cutting load data, eliminating the need for physical prototype testing and reducing design costs and time. Simultaneously, the simulation data covers more working conditions and accurately captures micro-stress changes. Stress and load characteristic analysis based on the simulation data quantifies the mechanical behavior of the cutting edge under different working conditions, avoiding the subjectivity of traditional experience-based design. By clearly defining the cutting edge width range and spatial orientation adjustment direction, the number of blind trial-and-error attempts is reduced. The final cutting edge width is determined through batch simulation comparison and weighted scoring, comprehensively balancing stress concentration and cutting stability. Adjusting the spatial tilt angle optimizes chip flow and heat dissipation characteristics, solving the problems of sudden increases in cutting force due to chip clogging and accelerated tool wear due to heat accumulation in traditional tools. The final determined spatial orientation parameters balance chip control and heat dissipation requirements, improving the overall cutting performance of the tool.

[0111] like Figure 2 As shown, embodiments of the present invention also provide a six-flute ball end mill design system with three evenly distributed flutes passing through the center for vibration resistance, comprising:

[0112] The multi-edge uniform distribution configuration module is used to employ a multi-edge uniform distribution strategy to arrange the six main cutting edges evenly around the tool axis, so that the cutting paths of each edge converge in the central area of ​​the tool to form the initial geometric configuration of the ball end mill.

[0113] The tool base construction module is used to generate the tool base structure based on the initial geometry by setting the diameter ratio between the cutting head and the clamping section, making the diameter of the clamping section slightly larger than the diameter of the cutting head, and introducing a micro-tilt structure in the transition region.

[0114] The structural parameter generation module is used to import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results.

[0115] The spiral cutting edge design module is used to design the main cutting edge as a spiral cutting edge structure in the finite element analysis model based on the adjustment parameters of the cutting edge structure. It determines the spiral angle value by combining the tool diameter and cutting conditions, and adjusts the geometric features of the cutting edge according to the finite element simulation results to generate the spiral cutting edge structure.

[0116] The chip breaker integrated module is used to place the helical cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, chip breaker grooves are arranged in an interlaced pattern on the surface of the cutting edge, and the distribution shape and contour size are coordinated to form a cutting edge structure with chip breaker grooves.

[0117] The cutting edge parameter determination module is used to simulate and analyze the stress distribution and cutting load of the cutting edge based on the cutting edge structure with chip breaker groove through finite element analysis model, and to set the width and spatial orientation parameters of the cutting edge to complete the comprehensive design of the anti-vibration ball end mill.

[0118] It should be noted that this system is a system corresponding to the above method. All implementation methods in the above method embodiments are applicable to this embodiment and can achieve the same technical effect.

[0119] Embodiments of the present invention also provide a computing device, including: a processor and a memory storing a computer program, wherein the computer program, when executed by the processor, performs the method described above. All implementations in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0120] Embodiments of the present invention also provide a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the method described above. All implementations in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0121] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, applied to a finite element analysis model, characterized in that... The method includes: Step 1: Employing a multi-edge distribution strategy, six main cutting edges are evenly arranged around the tool axis, causing their cutting paths to converge in the central region of the tool, forming the initial geometric configuration of the ball end mill. This includes: determining the circumferential distribution positions of the six main cutting edges at the ball end based on the multi-edge distribution strategy, ensuring a circumferential angle of 60 degrees between adjacent cutting edges to obtain the circumferential positioning results of each cutting edge; calculating the radial and axial coordinates of each main cutting edge based on the circumferential positioning results, controlling the extension trajectory of each edge from the outer edge of the ball end to the tool axis, converging in the central region of the ball end, and generating corresponding cutting edge line data; constructing the flank face geometry of each cutting edge based on the cutting edge line data, and designing the rake face geometry based on the flank face geometry to form a complete cutting edge unit; and axially superimposing the six cutting edge units evenly distributed circumferentially to finally form the initial geometric configuration of the ball end mill. Step 2: Based on the initial geometric configuration, the diameter ratio of the cutting head to the clamping section is set so that the diameter of the clamping section is slightly larger than the diameter of the cutting head. A micro-tilt structure is introduced in the transition region to generate the tool base structure. This includes: setting the ratio of the maximum diameter of the cutting head to the diameter of the clamping section to be within the range of 0.8 to 0.95 according to the initial geometric configuration; calculating the specific diameter of the clamping section based on the ratio and the diameter of the cutting head to form diameter parameters; designing a micro-tilt structure with an inclination angle of 1° to 3° in the transition region between the head and the clamping section based on the diameter parameters to generate transition region geometric parameters; and geometrically integrating the micro-tilt structure with the cutting head and the clamping section based on the diameter parameters and the transition region geometric parameters to form a complete tool base structure. Step 3: Import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results; Step 4: Based on the cutting edge structure adjustment parameters, design the main cutting edge as a helical cutting edge structure in the finite element analysis model. Determine the helical angle value by combining the tool diameter and cutting conditions, and adjust the cutting edge geometry based on the finite element simulation results to generate a helical cutting edge structure. This includes: setting the initial spatial orientation parameters of each main cutting edge in the finite element model according to the spatial posture requirements of each cutting edge determined by the cutting edge structure adjustment parameters; calculating and selecting the specific value of the helical angle within the range of 30° to 45° based on the initial spatial orientation parameters, combined with the total tool diameter and preset cutting conditions; and constructing each main cutting edge as a helical cutting edge structure with a constant helical angle based on the specific value. Step 5: Place the spiral cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, arrange the chip breaking grooves in an alternating pattern on the surface of the cutting edge, and coordinate the distribution shape and contour size to form a cutting edge structure with chip breaking grooves. Step 6: Based on the cutting edge structure with chip breaker grooves, the stress distribution and cutting load of the cutting edge are simulated and analyzed by finite element analysis model, and the width and spatial orientation parameters of the cutting edge are set to complete the comprehensive design of the anti-vibration ball end mill.

2. The design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, as described in claim 1, is characterized in that... The tool matrix structure is imported into a finite element analysis model for geometric and mechanical correlation analysis. Based on the analysis results, the adjustment parameters for the cutting edge structure are obtained, including: The tool matrix structure is imported into finite element analysis software, material properties, boundary conditions and cutting load conditions are set, and mechanical simulation is performed on the stress distribution, strain state and vibration response of the tool during the cutting process to obtain the initial simulation results. Based on the initial simulation results, equivalent stress distribution, cutting force fluctuation and mode shape characteristic data are extracted, stress concentration areas and vibration sensitive parts are identified, and they are associated and located on the geometry of the corresponding cutting edge to obtain the associated location results; Based on the correlation positioning results, the main causes of stress concentration and vibration sensitivity are analyzed, and the types and ranges of geometric parameters that need to be adjusted for each cutting edge are determined. The geometric parameters include the rake angle, clearance angle and cutting edge inclination angle. Within the defined range of values, multiple sets of parametric simulations were compared using the finite element model. The set of parameter values ​​that resulted in a more uniform stress distribution and reduced vibration amplitude was selected as the final adjustment parameters for the cutting edge structure.

3. The design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, as described in claim 2, is characterized in that... Based on the adjustment parameters of the cutting edge structure, the main cutting edge is designed as a helical cutting edge structure in the finite element analysis model. The helix angle value is determined by combining the tool diameter and cutting conditions, and the geometric features of the cutting edge are adjusted according to the finite element simulation results to generate the helical cutting edge structure, including: Based on the geometric characteristics of the helical blade structure, calculate and determine the blade width parameters that match it; The spiral blade structure and blade width parameters are substituted into the finite element model for cutting simulation. Based on the cutting force, stress distribution and chip removal characteristics data obtained from the simulation, the local geometry of the rake face and flank face is corrected. Based on the modified geometry and cutting edge parameters, a helical cutting edge structure that ultimately meets the requirements for continuous and smooth cutting is generated.

4. The design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, as described in claim 3, is characterized in that... The helical cutting edge structure is placed in a finite element analysis model to simulate the cutting process. Based on the simulation results, staggered chip breaker grooves are arranged on the surface of the cutting edge, and the distribution shape and contour size are coordinated to form a cutting edge structure with chip breaker grooves, including: The spiral cutting edge structure was imported into the finite element analysis model. The first cutting process was simulated by setting the cutting parameters, and the first simulation data including chip shape, cutting force and stress distribution were obtained. Based on the chip morphology and stress distribution characteristics in the initial simulation data, the staggered distribution pattern, preliminary spacing and basic outline dimensions of the chip breaker groove are determined, and the initial design parameters of the chip breaker groove are obtained. Based on the initial design parameters of the chip breaker groove, an initial geometric model of the chip breaker groove is constructed on the surface of the spiral cutting edge, and the geometric model is updated in the finite element analysis environment; A secondary cutting simulation was performed based on the updated geometric model. The distribution density, depth, and groove profile of the chip breaker groove were adjusted according to the chip breaking effect and cutting force changes in the secondary simulation data to generate chip breaker groove design parameters. Based on the chip breaker design parameters, chip breaker grooves with distribution patterns and contour dimensions are generated on the surface of the spiral cutting edge, ultimately forming a cutting edge structure with chip breaker grooves.

5. The design method for a six-flute ball end mill with three evenly distributed flutes passing through the center for vibration resistance, as described in claim 4, is characterized in that... Based on a cutting edge structure with chip breaker grooves, the stress distribution and cutting load at the cutting edge are simulated and analyzed using a finite element analysis model. The width and spatial orientation parameters of the cutting edge are set to complete the comprehensive design of an anti-vibration ball end mill, including: The cutting edge structure with chip breaker groove is imported into the finite element analysis model for cutting simulation to obtain simulation data including the stress distribution of the cutting edge and the cutting load. Based on the stress distribution and load characteristics in the simulation data, the mechanical behavior of the cutting edge under different working conditions is analyzed to determine the range of the cutting edge width and the direction of spatial orientation adjustment. Based on the spatial orientation adjustment direction, a set of candidate values ​​for the cutting edge width are generated in the range of 0.1mm to 0.3mm, and a width parameter scheme is formed by combining the tool diameter and cutting conditions; The width parameter schemes were substituted into the finite element model for simulation comparison. Based on the stress concentration and cutting stability in the comparison results, the final cutting edge width value was determined. Based on the final cutting edge width value, the chip flow and heat dissipation characteristics are determined by adjusting the spatial inclination angle of the cutting edge, thus forming the final spatial orientation parameters; The final cutting edge width value and spatial orientation parameters are applied to the cutting edge structure to complete the comprehensive design of the anti-vibration ball end mill.

6. A ball end mill design system with six flutes, three of which are evenly distributed and pass through the center for vibration resistance, wherein the system implements the method as described in any one of claims 1 to 5, characterized in that, include: The multi-edge uniform distribution configuration module is used to employ a multi-edge uniform distribution strategy to arrange the six main cutting edges evenly around the tool axis, so that the cutting paths of each edge converge in the central area of ​​the tool to form the initial geometric configuration of the ball end mill. The tool base construction module is used to generate the tool base structure based on the initial geometry by setting the diameter ratio between the cutting head and the clamping section, making the diameter of the clamping section slightly larger than the diameter of the cutting head, and introducing a micro-tilt structure in the transition region. The structural parameter generation module is used to import the tool matrix structure into the finite element analysis model, perform geometric and mechanical correlation analysis, and obtain the cutting edge structure adjustment parameters based on the analysis results. The spiral cutting edge design module is used to design the main cutting edge as a spiral cutting edge structure in the finite element analysis model based on the adjustment parameters of the cutting edge structure. It determines the spiral angle value by combining the tool diameter and cutting conditions, and adjusts the geometric features of the cutting edge according to the finite element simulation results to generate the spiral cutting edge structure. The chip breaker integrated module is used to place the helical cutting edge structure in the finite element analysis model to simulate the cutting process. Based on the simulation results, chip breaker grooves are arranged in an interlaced pattern on the surface of the cutting edge, and the distribution shape and contour size are coordinated to form a cutting edge structure with chip breaker grooves. The cutting edge parameter determination module is used to simulate and analyze the stress distribution and cutting load of the cutting edge based on the cutting edge structure with chip breaker groove through finite element analysis model, and to set the width and spatial orientation parameters of the cutting edge to complete the comprehensive design of the anti-vibration ball end mill.

7. A computing device, characterized in that, include: One or more processors; A storage device for storing one or more programs, which, when executed by one or more processors, cause the one or more processors to implement the method as described in any one of claims 1 to 5.

8. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a program that, when executed by a processor, implements the method as described in any one of claims 1 to 5.

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