针对压铸铝合金在切削力影响下加工精度低、表面质量不高等问题,提出在铣刀前刀面加工沟槽和V型阵列表面微织构的方法.通过三向力传感器监测并分析铣削过程中的铣削力变化情况,重点分析y向铣削力(F_y)频谱特性.将采集到的F_y 进行快速傅里叶变换,得到3种不同铣刀F_y 的频谱分析图,利用表面形貌和表面粗糙度评价表面微织构铣刀的铣削性能.结果表明:相较于普通铣刀在x、y和z方向的铣削力均值,沟槽阵列表面微织构铣刀的均值分别降低了3.8%、0.29%和11.7%,V型阵列表面微织构铣刀的均值分别降低了8.5%、14.3%和12.4%;在6倍主轴频率处的F_y高频幅值的大小关系为普通铣刀>沟槽阵列铣刀>V型阵列铣刀;采用微织构铣刀加工的表面,其表面粗糙度比普通铣刀的小,且V型阵列铣刀加工工件的表面质量最好.研究结果将为压铸铝合金精密铣削提供理论依据.

Aimed at the problems of low processing accuracy and surface quality of die-casting aluminum alloy under the influence of cutting force, a method of using surface micro-textured milling cutter with groove and V-shaped arrays on the rake face was proposed. The variations of milling forces were monitored and analyzed by using tri-direction-force transducer, and the spectrum characteristics of the y-direction milling force (F_y) was emphatically analyzed. The spectrum analysis diagrams of F_y of three different milling cutters were obtained by fast Fourier transform. The milling performance of the micro-textured milling cutters was evaluated by surface topography and surface roughness. The results show that compared with the average values in the x, y, and z directions of the conventional milling cutter, the values of the groove micro-structured milling cutter are reduced by 3.8%, 0.29%, and 11.7%, while those of the V-shaped micro-structured milling cutter are reduced by 8.5%, 14.3%, and 12.4%. The relationship between high frequency amplitudes of F_y at 6 times spindle frequency are proposed as conventional milling cutter>groove arrays milling cutter>V-shaped arrays milling cutter. Compared with the conventional milling cutter, the surface roughness is decreased when using micro-textured milling cutters, and the surface quality of the workpiece processed by the V-array milling cutter is the best. This paper will provide a theoretical basis for precision milling of die-cast aluminum alloys.