Finite Element Simulation And Experimental Research On Deformation For Milling Process Of Aluminium Alloy Thin-walled Parts

With the development of the advanced manufacturing technology,especially the development of aerospace technology, the thin-walled parts has been used extensively in various engineering. However, due to the poor stiffness, thin-walled parts are easy to be out of shape in machining under the influence of blank material properties,initial residual stress,cutting force and clamping force. Deformation for milling process is a complex problem in machinery manufacturing technology, the machining accuracy and the manufacture efficiency is affected by deformation for milling process. Therefore, studying on prediction and control of deformation for milling process,have important realistic meanings.2A12 aluminum alloy is a kind of high intensity deformation aluminum alloy, due to superior performance, has been used extensively in the thin-walled part machining. the processing technology of thin-walled parts characteristic and the causes of machining deformation, are described firstly in my paper, secondly, the present research status of domestic and overseas is introduced simply. Then,2A12 aluminum alloy thin-walled parts is taken as the research object,integral deformation and local deformation for milling process of aluminium alloy thin-walled parts have been systematically studied by theoretical analysis ,expermental research and finite element simulations.The effect on cutting force by different milling parameters is studied by the single-factor experimental method and the empirical equation of milling force about 2A12 aluminum alloy is achieved by regression experimental method, in given conditions which are limited to the particular cutting-tool material and the cutter teeth. The empirical equation provides the boundary conditions for FEA simulation. In the view of the thermo-mechanical and elastic-plastic theories,in order to establish the quenching-induced residual stress field of aluminum alloy blank, 2A12 aluminum alloy quenching processes simulate The simulation on quenching processes of 2A12 aluminum alloy blank is carried out by using FEA software ANSYS with residual stress calculated. The quenching-induced residual stress field provides the boundary conditions for FEA simulation on the integral deformation which is due to the initial residual stress for the thin-walled parts.Using the methods of finite element simulation and experimental,the integral deformation characteristics of the thin-walled parts have been studied in the conditions which the initial residual stress exists or not.That indicates the initial residual stress is the main factor of causing the integral deformation.The local deformation characteristics have been studied in the conditions which the residual stress doesnot exist,which indicates the milling force causes the manufacturing error that is unequal wall thickness of the thin-walled parts sidewall.