面向薄壁件变形控制的高速铣削残余应力分析与工艺优化  

Residual Stress Analysis and Process Optimization of High-Speed Milling for Deformation Control of Thin-Walled Parts

作　　者：郭建烨[1] 毛怡颖 高诗诗 侯宁 GUO Jianye;MAO Yiying;GAO Shishi;HOU Ning(Shenyang Aerospace University,Shenyang 110136,China)

机构地区：[1]沈阳航空航天大学,沈阳110136

出　　处：《航空制造技术》2025年第6期86-95,共10页Aeronautical Manufacturing Technology

基　　金：辽宁省教育厅高校基本科研项目面上项目(JYTMS20230257);沈阳市自然科学基金(24-102-6-01)。

摘　　要：切削加工过程产生的残余应力是引起薄壁件变形的主要因素之一,切削参数的选择对残余应力有直接影响,通过分析残余应力的变化规律并合理选择切削参数,进而减小工件切削后的表面残余应力,最终能实现控制薄壁件变形程度和保证加工精度的目的。首先基于McDowell模型建立了三维残余应力的理论模型,并通过铣削仿真过程分析了高速切削条件下,主轴转速、每齿进给量、轴向切深对残余应力的影响规律,结果表明,每齿进给量对残余应力的影响程度最大;然后根据理论模型和仿真分析的结果,以减小残余应力和同时增大材料去除率为优化目标,采用Pareto模拟退火算法对切削参数进行了双目标优化,并获取了一组最优解集;最后通过铣削试验对优化结果进行了验证,结果表明,优化算法求解的残余应力值与试验测量的残余应力值之间的误差率在合理范围内,证明了优化结果的可靠性和优化算法的可行性。Residual stress generated during the cutting process is one of the main factors causing deformation of thin-walled parts.The selection of cutting parameters has a direct impact on residual stress.By analyzing the variation law of residual stress and selecting cutting parameters reasonably,surface residual stress of the workpiece after cutting can be reduced,ultimately achieving the goal of controlling the degree of deformation of thin-walled parts and ensuring machining accuracy.Researches have been conducted on certain aspects,including change laws and influences of cutting force,cutting temperature and residual stress on the forming qualities of thin-walled parts.Based on previous studies,this paper proposed an improved algorithm to analyze the residual stress and optimize the process during formation of the thin-walled parts.Firstly based on McDowell model,this study established a theoretical model for three-dimensional residual stress,and analyzed the influence of spindle speed,feed rate per tooth and axial cutting depth on residual stress under high-speed cutting conditions through milling simulation;the results showed that the feed rate per tooth had the greatest impact on residual stress.Then based on the theoretical model and simulation analysis results,with the optimization objective of reducing residual stress and simultaneously increasing material removal rate,the Pareto simulated annealing algorithm was used for dual objective optimization of cutting parameters,and a set of optimal solutions was obtained.Finally,the optimization results were verified through milling experiments,and results showed that the error rate between residual stress values solved by the optimization algorithm and those measured by the experiment was within a reasonable range,indicating reliability of the optimization results and feasibility of the optimization algorithm.

关 键 词：高速切削 钛合金 切削参数 残余应力 工艺优化 

分 类 号：TG54[金属学及工艺—金属切削加工及机床]