极大径厚比薄壁件的加工变形仿真与试验研究  

Simulation and experimental research on machining deformation of thin-walled parts with large diameter to thickness ratio

作　　者：孙启梦 李蓓智[1] 周亚勤[1] 刘晓 SUN Qimeng;LI Beizhi;ZHOU Yaqin;LIU Xiao(College of Mechanical Engineering,Donghua University,Shanghai 201620,China;Shanghai Aero-Space Equipment Manufacturing General Co.Ltd.,Shanghai 201100,China)

机构地区：[1]东华大学机械工程学院,上海201620 [2]上海航天设备制造总厂有限公司,上海201100

出　　处：《东华大学学报（自然科学版）》2022年第1期85-92,共8页Journal of Donghua University(Natural Science)

基　　金：国家科技重大专项(2018ZX04011001)。

摘　　要：针对径厚比极大的铝合金薄壁件易加工变形的问题,开展基于有限元显示动力学的铣削过程仿真研究。在相同材料去除率下,分析转速、切深及每齿进给量的组合条件对切削力与变形的影响;采用单侧独立切削与双侧交替切削两种加工路径,在薄壁件不同高度处进行切削变形仿真计算。结果表明:较高的转速、较小的切深及适当的每齿进给量可保证加工效率并减小加工变形;采用内外表面双侧交替切削路径时的加工变形小于内外表面独立切削的变形。随着切削高度的下降,两种切削路径的变形差异逐渐减小,变形差值百分比由顶部42.7%降至中部11.1%。在仿真研究的基础上,进行工程试验与薄壁件加工误差测试,验证了仿真研究所确定的工艺参数及其内外表面双侧交替切削方案的可靠性。Aiming at the problem of easy machining deformation of aluminum alloy thin-walled parts with large diameter to thickness ratio, a simulation study of the milling process based on the finite element analysis method was carried out. The effect of the combined conditions of speed, depth of cut and feed per tooth on cutting force and deformation under the same material removal rate was analyzed. The path of one-sided independent cutting and two-sided alternate cutting were adopted to carry out the simulation calculation of cutting deformation of thin-walled parts at different height positions. The results show that a combination of a higher speed, a smaller depth of cut and an appropriate feed per tooth can maintain the machining efficiency and reduce the processing distortion;the deformation of the double-sided alternating cutting path is smaller than that of the independent cutting of the inner and outer surfaces. With the decrease of cutting height, the deformation difference between the two cutting paths gradually decreases, and the percentage of the deformation difference decreases from 42.7% at the top to 11.1% in the middle. Engineering experiments and machining error tests were carried out to verify the correctness of the simulation research and the double-sided alternating cutting path for the inner and outer surfaces.

关 键 词：薄壁件 铝合金 切削变形 工艺参数 有限元分析 

分 类 号：TG506[金属学及工艺—金属切削加工及机床]