毛坯开槽方式中零件加工变形的演变机理与控制方法  

EVOLUTION MECHANISM AND CONTROL STRATEGY OF WORKPIECE MACHINING DEFORMATION IN BLANK SLOTTING METHOD

作　　者：王华敏[1] 陶江 秦国华[1] 林锋[1] 吴铁军[2,3] 郑许 WANG Hua-min;TAO Jiang;QIN Guo-hua;LIN Feng;WU Tie-jun;ZHENG Xu(School of Aeronautical Manufacturing Engineering,Nanchang Hangkong University,Nanchang 330063,China;Department of Mechanical and Electrical Engineering,Dongguan Polytechni,Dongguan 523808,China;College of Mechanical&Electrical Engineering,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China;School of Materials Science and Engineering,Central South University,Changsha 410083,China;Guangxi Alnan Aluminium Co.,Ltd,Nanning 530031,China)

机构地区：[1]南昌航空大学航空制造工程学院,南昌330063 [2]东莞职业技术学院机电工程系,东莞523808 [3]南京航空航天大学机电学院,南京210016 [4]中南大学材料科学与工程学院,长沙410083 [5]广西南南铝加工有限公司,南宁530031

出　　处：《工程力学》2022年第5期233-247,共15页Engineering Mechanics

基　　金：国家自然科学基金项目(51765047);江西省主要学科学术和技术带头人资助计划项目(20172BCB22013);江西省重大研发计划项目(20203BBE53049,20192BBEL50001)。

摘　　要：广泛用作飞机薄壁整体结构件毛坯的铝合金厚板,在制造过程中出现的塑性变形不均匀性将导致残余应力的产生。高速铣削过程中残余应力的释放将引起飞机薄壁整体结构件的加工变形,这严重影响加工质量。因此,建立了毛坯释放变形后零件铣削的有限元仿真方法,挠度解析法的计算结果和实验测量的数据均验证了有限元仿真值无论是在趋势上还是变形量上均高度吻合。利用有限元方法揭示了开槽方式对毛坯释放变形的影响规律,分析了零件加工变形与毛坯释放变形之间的关系。结果表明:毛坯释放多大变形量,零件就能减小多大的变形量。在建立毛坯释放变形预测模型的基础上,提出了开槽方式的遗传算法优化方法,随机测试集表明神经网络的预测精度高达95%左右,而三框件在最佳开槽方式下能减小34.5%的变形。Residual stresses can be generated in aluminum alloy thick plates used widely as the blank of aeronautical thin-walled monolithic components because of the non-homogeneity of plastic deformation induced in the blank manufacturing process. The release of residual stress in high-speed milling process causes the machining deformation of aeronautical thin-walled monolithic component which can severely influence its machining quality. Therefore, the finite element simulation method of milling process is established for the thinwalled workpiece in the deformation-released blank. The finite element simulation values, as well as the calculation values obtained by the deflection analytical method, are verified to be highly agreed with the experimental measurement results in both trend and magnitude. The influence of slotting mode on the blank releasing deformation is revealed by the finite element method so that the relationship between the blank releasing deformation and the workpiece machining deformation is obtained. The result shows that the reduced workpiece machining deformation is the same as the blank releasing deformation. Based on the prediction model of blank releasing deformation, a genetic algorithm optimization method is proposed for the blank slotting mode. The random test set shows that the prediction accuracy of the neural network is about as high as 95% whereas the machining deformation of the three-frame workpiece can be reduced by 34.5% in the optimal slotting mode.

关 键 词：飞机薄壁整体结构件 铝合金厚板 残余应力 开槽法 毛坯释放变形 

分 类 号：TH161.3[机械工程—机械制造及自动化] V261.2[航空宇航科学与技术—航空宇航制造工程]