Abstract:

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.

Key words: surface micro-texture, milling die-casting aluminum alloy, milling force, spectrum characteristics, surface roughness