Existing research on machined surface topography, only consider its response to vibration or wear certain factors, both vibration and wear impact on machined surface topography exist ambiguity and uncertainty, it cannot solve the design conflicts of machined surface topography. For this, this paper analyzes blade installation error, tool wear, vibration and deformation to reveal effects of tip space trajectory, build a three-dimensional model of machined surface topography in simulation, extract its characteristic parameters, by simulation of different amplitudes and wear, found that axis amplitude is a key factor affecting surface residual height, flank wear affects contour distribution distance significantly, by specimen milling experiments, use vibration measuring instrument and ultra-depth microscopy to obtain vibration, wear characteristics and machined surface topography parameters under different cutting parameters, then use the gray system theory to get correlation analysis of the test data, results showed that the influence of tool wear on machined surface topography is prominent than tool vibration.
The existing safety evaluation of high-speed milling cutter mainly based on ISO15641 standards, which by idling experiments, then analysis and determine centrifugal force conditions what cause permanent deformation and fracture destructive of cutter, this method cannot be forecast and control the dynamic evolution of the milling cutter's safety and reliability, when cutting load changed suddenly.This paper using the high speed milling cutter's failure criteria and safety margin model of cutting hardened steel, analysed and evaluated coupled thermal field distribution caused by hardened steel surface feature that changed frequently and cutter's impact, fatigue, strength, stiffness, safety margin which cuased by mutated shock load of cutter, then forecast safety and reliability of high-speed milling cutter, and proposed the control method of safety and reliability that could milled hardened steel in high speed.
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