Multi-scale method for recognizing damage in high-efficiency milling cutter

Under the influence of a high-speed, interrupted-cutting impact load, the damage degree quickly increases following any structural damage in a milling cutter. The presence of structural damage must be explored given the fact that these conditions may result in irreparable and serious accidents if not immediately detected. Milling cutter damage has multi-scale characteristics. Therefore, the single-scale damage research method cannot reveal the formation and evolution of the multi-scale damage of a milling cutter, which makes it difficult to identify and control the damage of a milling cutter. The damage scales of a milling cutter are divided according to the multi-scale characteristics of milling cutter damage. Based on continuum mechanics, the dislocation theory, and molecular dynamics, the damage characterization method of the macrostructure, lattice structure, and mesoscopic structure of a milling cutter were proposed in this study. Utilizing the multi-scale finite element method and the force connection method, the loading boundary conditions of the multi-scale damage of a milling cutter were established in order to achieve a trans-scale load transfer. The damage characteristics of the macrostructure, lattice structure, and mesoscopic structure of the milling cutter were studied, and the critical value of the multi-scale damage characteristic variable of the milling cutter was obtained. Thereby, the damage position, types, and size and damage occurrence sequences of the milling cutter were revealed, and the damage formation process and the characteristics of the milling cutter were clarified. Based on this, a method for recognizing the multi-scale damage in a milling cutter was proposed and verified by experiments. The results showed that the above method could effectively identify multi-scale damage characteristics and reveal the formation and evolution process of the damage of a high-efficiency milling cutter.