Abstract: In order to explore the material removal mechanism and the effects of milling force and hole quality in the helical milling processes of SiCp/Al composites, the formation mechanism of the machined surface was studied by finite element simulation, and then the accuracy of the simulation was verified by experiments. The influences of process parameters on milling force, hole wall processing morphology and entrance and exit edge quality were explored. The results show that the milling force in the helical milling processes decreases with the increase of spindle speed, and increases with the increase of pitch and revolution speed. The uniformity of machined surface morphology increases with the increase of spindle speed, and decreases with the increase of pitch and revolution speed. The quality of the outlet edge increases with the increase of the spindle speed and the revolution speed, and decreases with the increase of the pitch. The inlet edge quality decreases with the increase of spindle speed and pitch, and the revolution speed has no effect on the inlet quality.

Key words: helical milling, milling force, surface formation mechanism, entrance and exit damage, composite material

摘要： 为了探究SiCp/Al复合材料螺旋铣削过程中材料去除机理以及铣削力和制孔质量影响规律，利用有限元仿真对加工表面形成机理进行研究，并通过试验验证了仿真的准确性。探索了工艺参数对铣削力、孔壁加工形貌、出入口棱边质量的影响规律，结果表明：螺旋铣削过程中铣削力随主轴转速增大而降低，随螺距和公转转速增大而增大；加工表面形貌均匀性随主轴转速增大而提高，随螺距和公转转速增大而降低；出口棱边质量随主轴转速和公转转速的增大而提高，随螺距增大而降低；入口棱边质量随主轴转速和螺距的增大而降低，公转转速对入口棱边质量没有影响。

关键词: 螺旋铣削, 铣削力, 表面形成机理, 出入口损伤, 复合材料