COMPOSITE MILLING HEADS FOR MACHINING LARGE FLAT SURFACES
Abstract
The article deals with the problems of increasing the productivity of milling the planes of workpieces with large dimensions. Such workpieces include the frames of centrifuges and metal-cutting machines, tables of paper-cutting machines, various plates and cases, frames, and parts of transport equipment. The dimensions of the planes of these parts usually exceed tens of centimeters and often reach meter values, which creates certain difficulties during machining. Since milling is one of the most efficient methods of machining, there is a problem of reducing the milling time of large workpieces. In this case, one-pass milling of planes with one cutter cannot always be implemented, since this requires a face mill of very large values: with a diameter of 400–630 mm and more. Multi-pass milling is often used, which reduces the quality of the surface and leads to an increase in machining time. Therefore, one of the options is the use of composite milling heads (CMH), which have their own drive and contain several face mills. For example, if the machining of mutually perpendicular flat surfaces is required, then an CMH containing four spindles with face mills installed on them is proposed. Each pair of adjacent cutters has trajectories of cutting knives that intersect. Such CMH allow obtaining a continuous machined surface with relative movement of the workpiece and the machine table. The maximum milling width of the CMH is almost twice the diameter of the face mill. CMH can work in any direction of longitudinal and transverse feed. The proposed CMH expands the technological capabilities of milling, as it allows the machining of large flat surfaces in mutually perpendicular directions. If there is a need to adjust the width of milling with the use of CMH (for example, when machining the planes of grooves with side walls), then the design of CMH with a rotating spindle block is proposed. In this CMH, three face mills are arranged in a row and are able to rotate together with the spindle block at a given angle α, thereby changing the milling width. The size of the milling width can vary from a maximum value equal to approximately the sum of the diameters of three cutters to a minimum value equal to one diameter of the cutter. The research determined the dependence of the milling width on the angle of rotation α (0°–360°) of the CMH spindle block, which contains three milling cutters with a diameter of Dfr = 315 mm. The proposed CMHs provide a reduction in the machining time of milling large flat surfaces by reducing the number of tool passes. A comparison of the normalization parameters of milling operations of the «OGSH»-type centrifuge bed fully confirms the advantage of using an CMH compared to a conventional face mill.
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