Abstract: Aiming at the problems of high tool costs caused by severe tool wear in high speed machining of difficult-to-cut materials such as a new type alloy cast iron, milling experiments on Cr15Mo were carried out with lower-cost cemented carbide tools. The effects of cutting parameters on cutting forces and surface roughness were investigated. The optimum parameter combination of achieving the grinding effectiveness(Ra=0.4 μm) was obtained, i.e. cutting speed vc=800 m/min, axial cutting depth ap=0.4 mm and feed rate f=0.6 mm/r. Furthermore, the experimental results were theoretically analyzed by using robust design optimization principle. The research results show that the theoretical analysis results are in good agreement with the experimental ones, which provides an effective way of exploring multi-objective parameter optimization for simultaneously realizing high speed, high quality and low cost in machining processes.

Key words: high-speed milling, cutting force, surface roughness, multi-objective parameter optimization, cutting mechanism

摘要： 针对高速切削新型合金铸铁类难加工材料时，因刀具磨损严重而导致刀具成本高的问题，采用成本较低的硬质合金刀具对Cr15Mo工件进行了铣削实验，研究了切削参数对切削力和表面粗糙度的影响，获得了可达到磨削加工效果（Ra=0.4 μm）的最佳参数组合，即切削速度vc=800 m/min，轴向切削深度ap=0.4 mm和进给量f=0.6 mm/r。基于稳健设计优化原理对实验结果进行了理论分析，研究结果表明：理论分析结果与实验结果具有很好的一致性，为同时实现高速、高质量和低成本加工的多目标参数优化方法提供了一种有效的途径。

关键词: 高速铣, 切削力, 表面粗糙度, 多目标参数优化, 切削机理