Stability Analysis and Structure Optimization of Unequal-Pitch End Mills

Area of Science:

• Mechanical Engineering
• Manufacturing Technology
• Vibration Analysis

Background:

• The damping performance of unequal tooth milling cutters is significantly influenced by pitch parameters.
• Improving vibration damping and dynamic balance in milling cutters remains a critical research area.

Purpose of the Study:

• To analyze the impact of pitch angles on milling cutter stability using lobe diagrams and spectral characteristics.
• To investigate methods for enhancing the dynamic balance accuracy of asymmetric unequal-pitch end mills.
• To optimize groove shape parameters for improved tool balance.

Main Methods:

• Analysis of pitch angle stability using lobe diagrams and spectral characteristics.
• Establishment of a centroid model for dynamic balance analysis of milling tools.
• Optimization of groove shape parameters to enhance dynamic balance accuracy.
• Modal and milling-force analysis to evaluate tool performance.

Main Results:

• Unequal-pitch end mills with asymmetric structures exhibit superior cutting stability.
• Optimization of groove shape parameters significantly improved tool dynamic balance accuracy.
• The optimized tool demonstrated a 17% reduction in relative vibration displacement and a 10% reduction in cutting force.
• Adjusting pitch angles and chip pocket parameters enhanced dynamic balance and reduced vibration.

Conclusions:

• Unequal tooth end mills, when optimized for pitch angles and chip pockets, offer enhanced cutting stability.
• The study confirms that optimizing tool design parameters can lead to significant improvements in vibration damping and dynamic balance.
• These advancements result in superior dynamic performance and higher machining accuracy.