MILLING TOOL DEVICE FOR AUXILIARY CHIP BREAKING AND TOOL SYSTEM FOR AUXILIARY CHIP BREAKING UNDER DIFFERENT LUBRICATING CONDITIONS

Abstract

The present invention discloses a tool device for auxiliary chip breaking and a tool system for auxiliary chip breaking under different lubricating conditions, which solves the problem that long chips affect the surface quality of a workpiece in the prior art and has the beneficial effects of realizing chip breaking and wide scope of application. The solution of the present invention is as follows: the tool device for auxiliary chip breaking includes a cutting mechanism for cutting the workpiece, arranged above the workpiece; a tool magazine mechanism, including a first rotating mechanism and a plurality of tools connected with the first rotating mechanism; and a tool changing mechanism, including a second rotating mechanism and manipulators connected with the second rotating mechanism, and arranged between the tool magazine mechanism and the cutting mechanism.

Claims

1. stool device for auxiliary chip breaking, comprising: a cutting mechanism for cutting a workpiece, located above the workpiece; a tool magazine mechanism, comprising a first rotating mechanism and a plurality of tools connected with the first rotating mechanism; and a tool changing mechanism, comprising a second rotating mechanism and manipulators connected with the second rotating mechanism, and arranged between the tool magazine mechanism and the cutting mechanism, wherein the manipulators can be moved to select the tools from the tool magazine mechanism and clamp the tools to cut off chips generated by the cutting mechanism to cut the workpiece.

2. The tool device for auxiliary chip breaking according to claim 1, wherein the second rotating mechanism is connected with a moving mechanism, and the moving mechanism drives the second rotating mechanism and then drives the manipulators to do reciprocating motion towards the tool magazine mechanism; or the second rotating mechanism is arranged in a motor box; the motor box is arranged on a bracket; and the motor box can do the reciprocating motion relative to the bracket, thereby driving the manipulators to do the reciprocating motion towards the tool magazine mechanism.

3. The tool device for auxiliary chip breaking according to claim 1, wherein the tool magazine mechanism comprises a tool pan; a plurality of first split rings are arranged in a circumferential direction of the tool pan; the tool is supported by the tool pan through the first split rings; the tools arranged in the plurality of first split rings have the same and/or different structure(s); the tool is a first tool with a chip breaking edge, and an angle formed by a flank face of the chip breaking edge and a main cutting edge of a second tool of the cutting mechanism is in direct proportion to a rake angle of the second tool; the radius of a chip-curling surface of the chip breaking edge of the first tool is inversely proportional to the brittleness of workpiece material; further, a shear angle between a shearing surface of the workpiece and a cutting speed direction can be determined by the following formula: $=\mathrm{arc}.Math..Math.\tan .Math..Math.\frac{\cos .Math..Math.{}_0}{-\sin .Math..Math.{}_0}$ wherein is the deformation coefficient of the material, and .sub.0 is the rake angle of the second tool.

4. The tool device for auxiliary chip breaking according to claim 3, wherein two manipulators are arranged reversely, and the two manipulators are arranged horizontally; the manipulators are provided with second split rings to match with the tool.

5. The tool device for auxiliary chip breaking according to claim 2, wherein the tool magazine mechanism and the cutting mechanism are supported by the bracket; the cutting mechanism can realize up-and-down motion relative to the bracket.

6. A tool system for auxiliary chip breaking under different lubricating conditions, comprising the tool device for auxiliary chip breaking of claim 1; a workbench, configured to fix the workpiece and arranged below the cutting mechanism; a nozzle, arranged at the side of the second tool of the cutting mechanism; and a lubricating mechanism, connected with the nozzle to provide lubricating oil.

7. The tool system for auxiliary chip breaking under different lubricating conditions according to claim 6, wherein the lubricating mechanism comprises a lubricating pump; the lubricating pump is connected with an oil cup and connected with a gas source processor through a solenoid valve; and the gas source processor is provided with an air inlet interface; a frequency generator is arranged between the solenoid vale and the lubricating pump to control the frequency of gas inputted from the air inlet interface.

8. The tool system for auxiliary chip breaking under different lubricating conditions according to claim 6, wherein the nozzle is connected with a nozzle pipeline; the nozzle pipeline is connected with a lubricating oil pipeline through a nozzle interface; and a fixing cover is arranged at one side of the cutting mechanism through a sucker; the nozzle axis has an angle of 40-50 with a workbench surface; the nozzle has a distance of 20 to 30 mm from the surface of the installed workpiece; the cutting mechanism comprises a motor box; the third rotating mechanism is arranged in the motor box to drive the second tool to rotate; and the sucker is arranged at the side of the motor box.

9. The tool system for auxiliary chip breaking under different lubricating conditions according to claim 6, wherein the workbench surface is provided with a workpiece clamp; a workpiece clamp opening is used for arranging a clamping slot of the workpiece; and a clamp screw is arranged at the side of the workpiece clamp to limit the workpiece; a pressing plate is arranged at the side of the clamping slot of the workpiece clamp, and can realize the rotation relative to the workpiece clamp; a locating block is movably arranged in the clamping slot and can be arranged at one side of the workpiece.

10. The tool system for auxiliary chip breaking under different lubricating conditions according to claim 9, wherein a dynamometer is arranged below the workpiece clamp, arranged between the workpiece clamp and the workbench, and connected with a controller; the controller is connected with a temperature sensor; and the workpiece is provided with a blind hole so that the temperature sensor can be installed on the workpiece.

Description

DESCRIPTION OF THE DRAWINGS

[0048] Drawings of the description forming part of the present application, are used for providing further understanding for the present application, and the exemplary embodiments of the present application and description thereof are used for explaining the present application, and do not form improper limitation to the present application.

[0049] FIG. 1 is an axonometric drawing of a tool for auxiliary chip breaking under different lubricating conditions and an experimental system;

[0050] FIG. 2 is an exploded assembly drawing of a lubricating mechanism;

[0051] FIG. 3 is an axonometric drawing of a tool magazine mechanism;

[0052] FIG. 4 is a top view of a tool pan;

[0053] FIG. 5(a) is an axonometric drawing of a first mandrel;

[0054] FIG. 5(b) is a front view of a first mandrel;

[0055] FIG. 6 is an axonometric drawing of a tool changing mechanism;

[0056] FIG. 7 is an axonometric drawing of a cutting mechanism;

[0057] FIG. 8 is an axonometric drawing of a force measuring mechanism;

[0058] FIG. 9 is a locating and clamping diagram of a workpiece;

[0059] FIG. 10 is an axonometric drawing of a milling dynamometer;

[0060] FIG. 11 is a schematic diagram of temperature measurement;

[0061] FIG. 12 is a section view of a workpiece;

[0062] FIG. 13 is a three-dimensional diagram of a tool with a chip breaking edge;

[0063] FIG. 14 is a section view of a tool in Embodiment 1 of a chip breaking edge;

[0064] FIG. 15 is a schematic diagram in Embodiment 1 of a chip breaking edge;

[0065] FIG. 16 is a section view of a tool in Embodiment 2 of a chip breaking edge;

[0066] FIG. 17 is a schematic diagram in Embodiment 2 of a chip breaking edge;

[0067] FIG. 18 is a diagram of a metal cutting deformation zone;

[0068] FIG. 19 is a schematic diagram of a shear zone;

[0069] FIG. 20 is a diagram for stress analysis of a shear zone;

[0070] FIG. 21 is a diagram of a velocity model; and

[0071] FIG. 22 is a schematic diagram of a milling air flow field.

[0072] In the drawings, lubricating mechanism I, tool magazine mechanism II, tool changing mechanism III, cutting mechanism IV, force measuring mechanism V, box body I-1, oil cup joint I-2, oil cup I-3, fixing screw I-4, washer I-5, fixing screw I-6, lubricating pump fixing cover I-7, precision MQL pump I-8, air flow regulation knob I-9, tee I-10, solenoid valve I-11, gas source processor I-12, air inlet interface I-13, two-way joint I-14, frequency generator I-15, pipeline I-16, pipeline I-17, pipeline I-18, oil regulation knob I-19, and lubricating pump outlet joint I-20.

[0073] First motor box II-1, first mandrel II-2, tool pan II-3, tool II-4, first split ring II-5, convex, part II-6, and clamping slot II-7.

[0074] Second motor box III-1, first manipulator III-2, second manipulator III-3, and second split ring III-4.

[0075] Third motor box IV-1, lubricating, oil pipeline IV-2, screw IV-3, washer IV-4, magnetic chuck IV-5, nozzle interface IV-6, nozzle pipe IV-7, second mandrel IV-8, nozzle IV-9, second tool IV-10, chip groove IV-10-1, chip breaking edge IV-10-2, chip breaking edge IV-10-3, rake face IV-10-4 of chip breaking edge, flank face IV-10-5 of chip breaking edge, rake face IV-10-6 of main cutting edge, tool nose IV-10-7, flank face IV-10-8 of main cutting edge, chip-curling surface IV-10-9 of chip breaking edge, and workbench IV-11.

[0076] Computer V-1, wire V-2, force information collector V-3, amplifier V-4, pressing plate V-5, cylindrical gasket V-6, pressing plate nut V-7, pressing plate screw V-8, workpiece V-9, flat plate screw V-10, small pressing plate screw V-11, locating screw V-12, workpiece clamp V-13, locating block V-14, dynamometer V-15, screw V-16, clamp screw V-17, flat plate V-18, and flat plate V-19.

[0077] Thermocouple VI-1, thermocouple 1 VI-1-1, thermocouple 2 VI-1-2, thermocouple 3 VI-1-3, information collector VI-2, and computer VI-3.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0078] It should be pointed out that, the following detailed description is exemplary and aims at providing further description to the present application. All technical and scientific terms used herein have the same meanings as those usually understood by those ordinary skilled in the art of the present application, unless otherwise specified.

[0079] It should be noted that, the terms used herein are only used for describing specific implementation, not intended to limit the exemplary implementation according to the present application. As used herein, a singular form is also intended to include a plural form, unless otherwise clearly specified in the context. In addition, it should be understood that, when the terms contain and/or include are/is used in the description, it specifies the existence of features, steps, operation, devices, components and/or their combinations.

[0080] As introduced in the background of the present invention, in view of the deficiencies in the prior art, in order to solve the above technical problems, the present application proposes a tool device and method for auxiliary chip breaking.

[0081] As shown in FIG. 1, the tool device for auxiliary chip breaking in the present invention includes a cutting mechanism IV for cutting a workpiece, arranged above the workpiece; a tool magazine mechanism II, including a first rotating mechanism and a plurality of tools connected with the first rotating mechanism; and a tool changing mechanism III, including a second rotating mechanism and manipulators connected with the second rotating mechanism, and arranged between the tool magazine mechanism II and the cutting mechanism, wherein the manipulators can be moved to select the tools from the tool magazine mechanism II and clamp the tools to cut off the chips generated by the cutting mechanism IV to cut the workpiece.

[0082] FIG. 3 is an axonometric drawing of a tool magazine mechanism; FIG. 4 is a top view of a tool pan; FIG. 5(a) and FIG. 5(b) are respectively an axonometric drawing and a front view of a first mandrel; and FIG. 6 is an axonometric drawing of a tool changing mechanism.

[0083] Description is made in combination with FIGS. 3-6. A first motor box II-1 realizes the rotation of a tool pan II-3 through an internal structure, and then, drives a first mandrel II-2 and a tool II-4 on the tool pan II-3 to rotate; and a second motor box III-1 realizes location transformation of a first manipulator III-2 and a second manipulator III-3 through an internal structure, and then, realizes the swapping of a processing tool, which can select different tools for processing according to the different conditions.

[0084] The second rotating mechanism is arranged in the second motor box III-1; the second motor box III-1 is arranged on a bracket; the bracket provides support by a machine tool; and the second motor box III-1 can do the reciprocating motion relative to the bracket, and then drives the two manipulators to do the reciprocating motion towards the tool magazine mechanism. Specifically, a chute is arranged on the bracket; the second motor box III-1 is partially inserted into the chute; and a linear reciprocating pushing mechanism is arranged at one side of the second motor box III-1, and the motor box is pushed to do the reciprocating motion through the pushing mechanism.

[0085] The tool magazine mechanism II includes a tool pan II-3; a plurality of first split rings II-5 are arranged in a circumferential direction of the tool pan II-3; the tool is supported by the tool pan II-3 through the first split rings II-5; the tools arranged in the plurality of first split rings II-5 have the same and/or different structure(s), and the length and size of the tool can also be set to be different.

[0086] Two manipulators are arranged reversely, and the two manipulators are arranged horizontally; the middle sections of the two manipulators are connected and connected with the second rotating mechanism through a connecting shaft.

[0087] Each of the manipulators is provided with a second split ring III-4 to match with the tool; the tool includes the first mandrel II-2 and a first tool connected with the first mandrel II-2 and having a chip breaking edge; a first half section of the first mandrel is in a circular table shape; a convex part II-6 is arranged in the middle section of the first mandrel; a clamping slot II-7 is formed in a circumferential direction of the convex part II-6; and the tool is matched with a first split ring II-5 or a second split ring III-4 through a clamping slot II-7. In this way, the tool changing mechanism can clamp the set tools from the tool magazine mechanism, and can also deliver the tools to the tool pan II-3 of the tool magazine mechanism, and then, select new tools. Specifically, the tools can be selected by manually operating the tool magazine mechanism and the tool changing mechanism or through a controller.

[0088] FIG. 7 is an axonometric drawing of a cutting mechanism. A third motor box IV-1 realizes the rotation of a second mandrel IV-8 through an internal structure, and then, drives a second tool IV-10 to rotate, thereby realizing the cutting. The lubricating oil provided by the, lubricating mechanism I is sprayed to a cutting zone through a lubricating oil pipeline IV-2, a nozzle pipe IV-7 and a nozzle IV-9, and a magnetic chuck IV-5 is fixed with a nozzle interface IV-6 through a screw IV-3 and a washer IV-4 and is sucked on a box body of the motor box IV-1.

[0089] A tool system for auxiliary chip breaking under different lubricating conditions includes the tool device for auxiliary chip breaking; a workbench IV-11, configured to fix the workpiece, and arranged below the cutting mechanism IV; a nozzle, arranged at the side of the second tool of the cutting mechanism; and a lubricating mechanism I, connected with the nozzle to provide lubricating oil.

[0090] As shown, in FIG. 1, the lubricating mechanism I provides the lubricating oil for milling to cool and lubricate; the tool magazine mechanism II realizes the storage of the tool; the tool changing mechanism III realizes the swapping of the tools; the cutting mechanism IV is used for milling the workpiece; and a force measuring, mechanism IV mainly measures the milling force when the workpiece is milled.

[0091] FIG. 2 is an exploded assembly drawing of a lubricating mechanism.

[0092] As shown in FIG. 2, the lubricating mechanism includes a box body I-1, an oil cup joint I-2, an oil cup I-3, a fixing screw I-4, a washer I-5, a fixing screw I-6, a lubricating pump fixing cover I-7, a precision MQL pump I-8, an air flow regulation knob I-9, a tee I-10, a solenoid valve I-11, a gas source processor I-12, an air inlet interface I-13, a two-way joint 1-14, a frequency generator I-15, a pipeline I-16, a pipeline I-17, a pipeline I-18, an oil regulation knob I-19, and a lubricating pump outlet joint I-20.

[0093] The air inlet interface I-13 is fixed to the gas source processor I-12, and high-pressure gas enters the gas source processor I-12 through the air inlet interface I-13 to filter, thereby providing the high-pressure gas for the lubricating mechanism. The gas source processor I-12 is connected with the solenoid valve I-11 through the two-way joint I-14 to control the entry of the gas; a tee I-10 is connected at the outlet of the solenoid valve I-11; the high-pressure gas enters the frequency generator I-15 through the outlet pipeline I-16 of the tee I-10; the input frequency of the gas is controlled through the frequency generator I-15; and the high-pressure gas enters the precision MQL pump I-8 through the pipeline I-17 after exiting from the frequency generator I-15. In addition, the high-pressure gas enters the precision MQL pump I-8 through another outlet pipeline I-18 of the tee I-10; one end of the oil cup joint I-2 is in threaded connection, and the other end is in threaded connection with the lubricating pump fixing cover I-7; the lubricating pump fixing cover I-7 is connected with the precision MQL pump I-8 through the two fixing screws I-6 and fixed to the box body I-1 through the two fixing screws I-4 and the washer I-5; the volume of the high-pressure gas is adjusted by adjusting the air flow regulation knob I-9; the volume of the lubricating oil is adjusted by adjusting the oil regulation knob I-19; and finally, the lubricating oil is provided to the cutting mechanism IV by connecting the lubricating pump outlet joint I-20 with the nozzle joint IV-6. By arranging the frequency generator and the solenoid valve, the lubrication under different conditions can be effectively realized, such as dry cutting, casting type lubrication, MQL and nanofluid MQL conditions.

[0094] FIG. 8 is an axonometric drawing of a force measuring mechanism; FIG. 9 is a locating and clamping diagram of workpiece; and FIG. 10 is an axonometric drawing of a dynamometer.

[0095] Description is made in combination with FIGS. 8-10. A dynamometer V-15 is fastened on a workbench IV-11 with a screw V-16. A workpiece clamp V-13 is fixed on the workbench of the dynamometer V-15; the workpiece V-9 is placed on the workbench of the dynamometer V-15; and six degrees of freedom of the workpiece V-9 can realize the complete locating through the workpiece clamp V-13 and the workbench of the dynamometer V-15. An X axis direction of the workpiece V-9 is clamped with two locating screws V-12, and in a Y direction of the workpiece, the workpiece V-9 is, clamped with a workpiece clamp screw V-17. One surface of a locating block V-14 comes into contact with the side of the workpiece V-9; the other surface comes into contact with the two locating screws V-12; and the locating, screws V-12 are tightened to clamp the locating block V-14 in the X direction of the workpiece V-9. The workpiece V-9 is clamped with three pressing plates V-5 in a Z direction, and the three pressing plates V-5 constitute a self-adjusting pressing plate by virtue of a flat plate V-18, a flat plate V-19, a cylindrical gasket V-6, a pressing plate screw V-8 and a pressing plate nut V-7. When the length, width and height of the workpiece V-9 are changed, adjustable equipment can be realized through the two clamp screws V-17, the two locating screws V-12 and the three pressing plates V-5, thereby meeting the requirements of change in size of the workpiece V-9. The locating block V-14 is clamped with a small pressing plate screw V-11 and the locating screw V-12. When the workpiece V-9 suffers from a cutting force, a measurement signal is transmitted to an information collector V-3 through an amplifier V-4 and finally to a computer V-1 through a wire V-2, and the size of the cutting force is displayed

[0096] FIG. 11 is a diagram of a temperature measurement system, and FIG. 12 is a section view of the workpiece.

[0097] Description is made in combination with FIGS. 11-11 Three blind holes are provided in the workpiece. Three thermocouples VI-1-1, VI-1-2 and VI-1-3 are located in the blind hole of the workpiece. A working end of the thermocouple is located at 0.5 mm below the surface of the workpiece V-9. When the second tool cuts the workpiece to a certain extent and cuts the thermocouple, the thermocouple detects the temperature of the second tool, and transmits a heat signal to the information collector, and finally, the temperature of the working end of the thermocouple is displayed on the computer. The three thermocouples can be adopted to measure the cutting heat in an end face milling for three times, to obtain three sets of measured data, thereby saving the time and avoiding the error arising from the installation difference.

[0098] FIG. 13 is a three-dimensional diagram of a tool with a chip breaking edge. FIG. 14 is a section view of a tool in Embodiment 1 of a chip breaking edge. FIG. 15 is a schematic diagram in Embodiment 1 of a chip breaking edge.

[0099] Description is made in combination with FIGS. 13-15. In Embodiment 1 of a chip breaking edge, the flank face IV-10-5 of the chip breaking edge forms an angle with the main cutting edge (the second tool for cutting the workpiece) IV-10-7 and forms an angle with the rake face IV-10-4 of the chip breaking edge, namely, a tool nose angle of the chip breaking edge. During milling machining, the main cutting edge IV-10-7 cuts the workpiece to form the chips: the chips flow out along the rake face IV-10-6 of the main cutting edge; the flow velocity of the chips is .sub.c; the chips are cut off by the chip breaking edge IV-10-2 in the process of flowing out along the rake face IV-10-6 of the main cutting edge, cut into smaller chippings and then discharged from a chip groove IV-10-1 by the rotation of the tool with the chip breaking edge. When the rake angle .sub.0 is relatively large, the angle should also be relatively large, and on the contrary, when the rake angle .sub.0 is relatively small, the angle should be relatively small. The chip breaking edge is suitable for the milling machining when the depth of cut .sub.p is large.

[0100] FIG. 16 is a section view of a tool in Embodiment 2 of a chip breaking edge, and FIG. 17 is a schematic diagram in Embodiment 2 of a chip breaking edge.

[0101] Description is made in combination with FIGS. 16-17. The tool nose IV-10-7 cuts the workpiece to form the chips; the chips flow out along the rake face IV-10-6 of the main cutting edge; and the flow velocity of the chips is .sub.c. According to the chip-curling principle, the chips bend according to the shape of a chip-curling surface IV-10-9 of the chip breaking edge in the process of flowing out along the rake face IV-10-6 of the main cutting edge, wherein the radius of the chip-curling surface IV-10-9 of the chip breaking edge is R; and the chip breaking edge IV-10-3 applies a certain binding force to the flowing chips, so that the strain of the chips is increased, and the curling radius of the chips is decreased, thereby forming a C shape. After the chips are severely deformed through a deformation zone I and a deformation zone II, the hardness is increased, the plasticity is reduced and the performance is brittle. During the discharge of the chips, when the chips encounter the flank face of the tool, a transitional surface on the workpiece, or a surface to be processed and other obstacles, if the strain of a part exceeds a breaking strain value of the chip material, the chips may be broken off The selection of the radius R of the chip-curling surface IV-10-9 of the chip breaking edge is related to the material performance. If the brittleness of the material is smaller, the R value is larger, and the degree of chip curling is larger, which is more beneficial to the chip breaking. The chip breaking edge is suitable for milling machining when the depth of cut .sub.p is relatively small. Meanwhile, if the brittleness of the workpiece material is larger (if the breaking strain value is smaller), the chip thickness is larger and the curling radius of the chips is smaller, then the chips are easier to break off.

[0102] The size diameters in Embodiment 1 of the chip breaking edge and Embodiment 2 of the chip breaking edge shall adapt to the cutting dosage; otherwise, the chip breaking effect may be affected.

[0103] FIG. 18 is a diagram of a metal cutting deformation zone. When the metal material is cut with the tool on a machine tool, a cutting layer is extruded by the rake face of the tool; and the cutting zone has three different deformation zones, which, are the deformation zone I, the deformation zone II and a deformation zone III, wherein, the deformation zone I is a zone between OA and OM in the cutting layer, an OA line is a start line for shear slip of metal, and an OM line is a terminating line for grain shear slip of the metal, which is a zone to generate the plastic deformation and the shear slip. The deformation zone I is the largest deformation zone; the grain is lengthened; and meanwhile, a lot of cutting heat is generated, but the zone is very narrow. which is probably only 0.2-0.02 mm wide. The deformation zone II is a contact zone of the tool/chips, and the metal material discharged by the rake face through the deformation zone I forms the deformation zone II at the place close to the rake face. In the area, under the friction and extrusion with the rake face, the deformation degree of the metal in the cutting layer is increased, the fibration is formed in a direction parallel to the rake face, and even, a stagnant layer sometimes appears. The deformation zone III is a contact zone of the tool/chips, which is a zone to generate the deformation of the processed surface layer close to the cutting edge due to the extrusion and friction of the cutting edge and the flank face, and the metal in the cutting layer is further suffered from the friction and extrusion of the flank face to generate the elastic resilience, which has a large influence on the quality of the finished surface of metal. The three deformation zones have their characteristics, and have interaction and mutual influence. Various physical phenomena in the cutting process are closely related to the deformation of the metal layer.

[0104] FIG. 19 is a schematic diagram of a shear zone; FIG. 20 is a diagram for stress analysis of a shear zone; and FIG. 21 is a diagram of a velocity model.

[0105] Description is made in combination with FIGS. 19-21. In the deformation zone I, simple analysis is conducted to the chip formation process according to a Merchant cutting model. It is assumed that the material is sheared along the shear plane expanded from a cutting edge to a free surface of the workpiece, namely, the deformation zone I in the metal cutting is taken as the shearing surface. An angle between the shearing surface and the cutting speed direction is called the shear angle. The size of the shear angle can be used for analyzing the degree of chip deformation, and calculating the cutting force. The shear deformation is generated in a zone. The material in the cutting layer generates the plastic deformation from a CD surface, namely, an initial shear plane of the deformation zone I; and the deformation of an EF surface is stopped. The EF surface is a terminating shear plane of the deformation zone I. At this time, the shear strain shall reach the maximum. The shear strains on CD, AB and EF surfaces shall be respectively:

[00002]$\begin{array}{cc}{}_{\mathrm{CD}}=0,{}_{\mathrm{AB}}=\frac{\cos .Math..Math.{}_0}{2.Math..Math.\sin .Math..Math..Math..Math.\cos \left(-{}_0\right)},{}_{\mathrm{EF}}=\frac{\cos .Math..Math.{}_0}{\sin .Math..Math..Math..Math.\cos \left(-{}_0\right)}& \left(1\right)\end{array}$

[0106] Plastic work W.sub.1 of the deformation zone I: W.sub.1=k.sub.AB.Math..sub.AB, wherein k.sub.AB is the shear strain on the shear plane AB, and .sub.AB is an average strain on the AB.

[00003]$\begin{array}{cc}{\stackrel{\_}{\mathrm{.Math.}}}_{\mathrm{AB}}=\frac{{}_{\mathrm{EF}}}{2.Math.\sqrt{3}}=\frac{\cos .Math..Math.{}_0}{2.Math.\sqrt{3}.Math.\sin .Math..Math..Math..Math.\cos \left(-{}_0\right)}& \left(2\right)\end{array}$

[0107] The shear zone is surrounded by the two parallel planes CD and EF, and the chips are formed in the shear zone. To simplify the calculation, it is assumed that the formation of the chips is continuous, and appropriately in a plane strain state.

[0108] The strain rate of the shear zone is required, and the following relational expression can be obtained according to the Von Mises stress yield criterion:

=/{square root over (3)}, {dot over ()}={dot over ()}/{square root over (3)}(3)

[0109] Wherein and {dot over ()} are respectively the strain and the strain rate of the shear zone; and {dot over ()} are respectively the shear strain and the shear strain rate of the shear zone. Any point is taken in the shear zone to calculate the strain and the strain rate of such point in the shear zone, and then, the shear strain and the shear strain rate along the shearing surface AB can be obtained.

[0110] Since upper and lower boundaries CD and EF in the shear zone and the shearing surface AB are parallel to each other, the average shear strain rate can be expressed with the equation of obtaining the flow velocity, namely, as shown in the following formula:

[00004]$\begin{array}{cc}{\stackrel{\_}{}}_{\mathrm{avg}}=\sqrt{{\left(\frac{.Math..Math.v_z}{{}_y}+\frac{.Math..Math.v_y}{{}_x}\right)}^2+4.Math.{\left(\frac{.Math..Math.v_x}{{}_y}\right)}^2}& \left(4\right)\end{array}$

[0111] Wherein .sub.avg is the average shear strain rate, and .sub.x and .sub.y are the flow velocity of a particle in an X and Y direction. In order to calculate the average shear strain rate, .sub.x=.sub.s.Math.cos , .sub.y=.sub.s.Math.sin , x=s.sub.1/sin , y=s.sub.1/cos is taken, wherein .sub.s is the shear speed, and s.sub.1 is the width of the shear zone, namely, a distance between the boundaries CD and EF of the shear zone. In order to obtain the average shear strain, the shear speed .sub.s should be obtained.

[0112] The average shear strain rate is:

[00005]$\begin{array}{cc}{\stackrel{\_}{}}_{\mathrm{avg}}=\frac{v.Math..Math.\cos .Math..Math.{}_0}{.Math..Math.s_1.Math..Math.\cos \left(-{}_0\right)}& \left(5\right)\end{array}$

[0113] The average shear strain .sub.AB along the shear line AB can be expressed with the product of the average shear strain rate and the time that the particle passes through the shear zone, as shown in the following formula:

[00006]$\begin{array}{cc}{}_{\mathrm{AB}}={\stackrel{\_}{}}_{\mathrm{avg}}.Math.\frac{.Math..Math.x}{2.Math..Math.v}=\frac{v.Math..Math.\cos .Math..Math.{}_0}{.Math..Math.s_1.Math.\cos \left(-{}_0\right)}.Math.\frac{.Math..Math.x}{2.Math..Math.v}=\frac{\cos .Math..Math.{}_0}{2.Math..Math.\sin .Math..Math..Math..Math.\cos \left(-{}_0\right)}& \left(6\right)\end{array}$

[0114] So a strain equation along an AB line is:

[00007]$\begin{array}{cc}{\mathrm{.Math.}}_{\mathrm{AB}}=\frac{1}{2.Math.\sqrt{3}}.Math.\frac{\cos .Math..Math.{}_0}{\cos .Math..Math.\left(-{}_0\right).Math.\sin .Math..Math.}& \left(7\right)\end{array}$

[0115] A strain rate equation along an AB line is:

[00008]$\begin{array}{cc}{\stackrel{.}{\mathrm{.Math.}}}_{\mathrm{AB}}=\frac{1}{\sqrt{3}}.Math.\frac{{\cos }^2.Math..Math.{}_0}{{\cos }^2.Math..Math.\left(-{}_0\right)}.Math.\frac{v}{a_c}& \left(8\right)\end{array}$

[0116] The shear angle in the above formula can be determined by the following formula.

[00009]$\begin{array}{cc}=\mathrm{arc}.Math..Math.\tan .Math..Math.\frac{\cos .Math..Math.{}_0}{-\sin .Math..Math.{}_0}& \left(9\right)\end{array}$

[0117] Wherein is the deformation coefficient of the material and related to the material, and .sub.0 is the rake angle of the tool.

[0118] The plastic deformation of the shear zone increases the temperature of the shearing surface, and the temperature change value T.sub.sz of the shear zone related to the shear force can be calculated by a formula (10).

[00010]$\begin{array}{cc}.Math..Math.T_{\mathrm{sz}}=\frac{1-{}_T}{.Math..Math.{\mathrm{Sa}}_c.Math.a_w}.Math.\frac{F_s.Math.\cos .Math..Math.{}_0}{\cos \left(-{}_0\right)}& \left(10\right)\end{array}$

[0119] Wherein .sub.T value is:

[00011]$\begin{array}{cc}{}_T=0.5-0.35.Math..Math.\log \left(R_T.Math.\tan .Math..Math.\right)& 0.04R_T.Math..Math.\tan .Math..Math.10.0\\ {}_T=0.3-0.15.Math..Math.\log \left(R_T.Math.\tan .Math..Math.\right)& R_T.Math..Math.\tan .Math..Math.>10.0\end{array}\};$

R.sub.T is the coefficient of dimensionless heat:

[00012]$R_T=\frac{.Math..Math.{\mathrm{SVa}}_c}{K};$

is the density of the workpiece material (Kg/m.sup.3); K is the thermal conductivity of the workpiece piece (m.sup.2.Math. C.); S is specific heat (g.Math. C.); and V is the cutting speed.

[0120] So, the expression of the average temperature T.sub.AB of the shearing surface is:

T.sub.AB=T.sub.w+T.sub.sz (11)

[0121] Wherein T.sub.w is the environmental temperature ( C.), and is the coefficient of converting the plastic work to the heat, and is 0.7.

[0122] The flow stress equation along the AB line is:

[00013]$\begin{array}{cc}{k}_{\mathrm{AB}}=\frac{1}{\sqrt{3}}.Math.{{}_0\left(1+\frac{{\mathrm{.Math.}}_{\mathrm{ab}}}{{\mathrm{.Math.}}_0}\right)}^n.Math.{\left(\frac{{\stackrel{\stackrel{.}{\_}}{\mathrm{.Math.}}}_{\mathrm{ab}}}{{\stackrel{\stackrel{.}{\_}}{\mathrm{.Math.}}}_0}\right)}^m.Math.{\left(1-\frac{T_{\mathrm{AB}}}{T_m}\right)}^l& \left(12\right)\end{array}$

[0123] Wherein .sub.0 is an initial yield stress (1000 MPa); .sub.0 is an initial strain

[00014]${\mathrm{.Math.}}_0=\frac{{}_0}{E};$

n is a strain index (0.1); {dot over ()} is a strain speed; {dot over ()}.sub.0 is a yield strain speed; m is a strain speed index (0.0143); T is a cutting temperature; T.sub.m is a melting temperature (related to the material); and 1 is a temperature softening coefficient (0.75).

[0124] The shear force on a shear plane is:

[00015]$\begin{array}{cc}{F}_s=k_{\mathrm{AB}}.Math.l_{\mathrm{AB}}.Math.a_w=\frac{k_{\mathrm{ab}}.Math.a_p.Math.a_w}{\sin .Math..Math.}& \left(13\right)\end{array}$

[0125] Wherein k.sub.AB is the shear force along the AB line; I.sub.AB is the length of the shearing surface AB; and .sub.w is the cutting width.

[0126] Three speeds are provided in the cutting process, which are respectively the cutting speed v, the cutting speed v.sub.c and the shear speed v.sub.s. The cutting speed is a linear speed of the first tool, and according to the continuous conditions, the three speeds are connected end to end to form a closed triangle. The equations of the cutting speed and the shear speed are:

[00016]$\begin{array}{cc}{v}_c=\frac{\sin .Math..Math.}{\cos .Math..Math.\left(-{}_0\right)}.Math.v& \left(14\right)\\ v_s=\frac{\cos .Math..Math.{}_0}{\cos .Math..Math.\left(-{}_0\right)}.Math.v& \left(15\right)\end{array}$

[0127] A shear energy Es is expressed as the function of the shear force and the shear speed;

E.sub.s=F.sub.s.sub.2 (16)

[0128] An angle of the shearing surface AB and a resultant force R of the shearing surface is called a cutting angle:

=+.sub.0 (17)

[0129] It can be known from material mechanics that

[00017]$+-{}_0=\frac{}{4}=.$

[0130] A resultant tool force R of the shear zone can be expressed as:

[00018]$\begin{array}{cc}R=\frac{F_s}{\cos .Math..Math.}=\frac{k_{\mathrm{ab}}.Math.a_p.Math.a_w}{\sin .Math..Math..Math..Math.\cos .Math..Math.}& \left(18\right)\end{array}$

[0131] It can be inferred according to the force-balance principle on the shearing surface that, the relation among the cutting force (F.sub.c) in the cutting speed direction, the cutting force (F.sub.t) in the cutting thickness direction and the resultant tool force R is obtained.

[00019]$\begin{array}{cc}\{\begin{array}{c}{F}_c=R.Math..Math.\cos .Math..Math.\left(-{}_0\right)\\ F_t=R.Math..Math.\sin .Math..Math.\left(-{}_0\right)\end{array}& \left(19\right)\end{array}$

[0132] In the deformation zone II, the chips generated by the metal formation in the cutting layer flow out along the rake face at the speed V.sub.c, and the flow velocity of the chip bottom close to the rake face is much more lower than that of other parts of the chip, which is called a stagnation phenomenon. The chips in the layer are called the stagnant layer. Serious plastic deformation occurs in the thin area of the stagnant layer of the chips on the rake face, which is also called secondary plastic deformation. A bonding phenomenon occurs between a chip bottom surface and the rake face under the conditions of high temperature and high pressure, and a bonding part of the chip bottom surface on the tool and upper metal generate the internal friction. The chip thickness .sub.ch of the deformation zone, contact length l.sub.f of the tool and the chips and the shear strain rate {dot over ()}.sub.HG of the shear speed in the deformation zone are respectively:

[00020]$\begin{array}{cc}{a}_{\mathrm{ch}}=\frac{a_c.Math..Math.\cos .Math..Math.\left(-{}_0\right)}{\sin .Math..Math.}& \left(20\right)\\ l_f=\frac{a_c.Math..Math.\sin .Math..Math.\frac{}{4}}{\sin .Math..Math..Math..Math.\sin .Math..Math.\left(\frac{}{4}+-{}_0\right)}& \left(21\right)\\ {\stackrel{.}{}}_{\mathrm{HG}}=\frac{V_c}{.Math.a_{\mathrm{ch}}}& \left(22\right)\end{array}$

[0133] Wherein is the ratio of the thickness of the deformation zone II of a tool-chip contact surface and the chip thickness .sub.ch, and =0.05.

[0134] The friction force F.sub.f between the tool and the chips is:

[00021]$\begin{array}{cc}{F}_f=K_{\mathrm{HG}}.Math.\frac{l_f}{2}.Math.a_w+\frac{1}{2}.Math.K_{\mathrm{HG}}.Math.\frac{l_f}{2}.Math.a_w=\frac{3}{4}.Math.K_{\mathrm{HG}}.Math.\frac{l_f}{2}.Math.a_w& \left(23\right)\end{array}$

[0135] Wherein K.sub.HG is the shear flow stress of the deformation zone II, K.sub.HG=.sub.HG/{square root over (3)}.

[0136] Therefore, the energy consumed by the tools/chip contact zone is:

[00022]$\begin{array}{cc}{E}_{\mathrm{HG}}=F_f.Math.V_c=\frac{3.Math..Math.{}_{\mathrm{HG}}.Math.l_f.Math.a_w.Math.V_c}{4.Math.\sqrt{3}}=\frac{\sqrt{3}.Math.{}_{\mathrm{HG}}.Math.l_f.Math.a_w.Math.V_c}{4}& \left(24\right)\end{array}$

[0137] The average temperature of the chips is:

[00023]$\begin{array}{cc}.Math..Math.T_c=\frac{F_f.Math..Math.\sin .Math..Math.}{.Math..Math.{\mathrm{Sa}}_c.Math.a_w.Math..Math.\cos .Math..Math.\left(-{}_0\right)}& \left(25\right)\end{array}$

[0138] The maximum temperature rises T.sub.M of the chips is:

[00024]$\begin{array}{cc}\log \left(\frac{.Math..Math.T_M}{.Math..Math.T_C}\right)=0.06-0.195.Math..Math..Math..Math.{\left(\frac{R_T.Math.a_{\mathrm{ch}}}{l_f}\right)}^{\frac{1}{2}}+0.5.Math..Math.\log .Math..Math.\left(\frac{R_T.Math.a_{\mathrm{ch}}}{l_f}\right)& \left(26\right)\end{array}$

[0139] Therefore, the average temperature T.sub.int of the chips is:

T.sub.int=T.sub.w+T.sub.sz+0.7T.sub.M (27)

[0140] FIG. 22 is a schematic diagram of a milling air flow field.

[0141] Description is made according to FIG. 22. The air around the tool is originally still, but the tool that rotates at high speed may cause the air to flow; and the flow velocity of the air closer to the cutting-edge part is higher, thereby forming a closed annular area around the tool. The existence of this area has a blocking effect for the entry of the cutting fluid, and the cutting fluid cannot enter the tool/workpiece interface, thereby causing the machining burn. Therefore, an appropriate cutting fluid injection method is adopted, namely, the best position of the nozzle IV-9 can increase the proportion that the cutting fluid enters the processing zone, thereby playing a very important effect to improve the cooling and lubricating effects and improve the surface quality of the workpiece. The distribution of air flows around the milling zone can be seen from the figure: an air barrier is located at the outermost layer to hinder the cutting fluid from entering the cutting zone. Therefore, the position of the nozzle IV-9 shall not be outside the air barrier; influent flow is an airflow pointed to the surface of the tool in an airflow direction, which is beneficial to the entry of the cutting fluid. The cutting fluid follows into the airflow to reach the places around the tool and at a tool groove, thereby achieving the effect of transporting the cutting fluid. Further, the cutting fluid is transported into the cutting zone through a radial flow, and the radial flow is an airflow having an axial airflow direction; part of cutting fluid is adhered to the workpiece surface to form a layer of dense lubricating oil film, thereby playing a friction-reducing and anti-wear role, and cooling and lubricating the tool/workpiece interface; and part of cutting fluid flows out with the returning flow; the returning flow is an airflow having an airflow direction back on to the surface of the tool; the existence of the returning flow enables part of cutting fluid to flow out of the cutting zone, and simultaneously plays a role of hindering the cutting fluid from entering the cutting zone. Therefore, the injection of the cutting fluid shall be prevented from coming into contact with the returning flow. According to the measurement, when the axis of the nozzle IV-9 forms a certain angle (40-50 and a certain distance (20-30 mm) with the workpiece surface, the air flow field may play a role of transporting the cutting fluid. Meanwhile, the retuning flow has the minimum obstruction for the cutting fluid, and the cutting fluid enters the cutting zone more easily and plays the best lubricating and cooling effects.

[0142] The above only describes preferred embodiments of the present application, and is not used for limiting the present application. For those skilled in the art, various changes and variations can be made to the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.