Deformation Studies, Based On Cutting Force Of The Thin-walled Deep Cavity Component Processing

Because of the low rigidity, the thin-walled deep-recessed parts are easily deformable during the machining process, and it is very difficult to reduce the machining deformation and improve the process precision. Supported by the scientific research item and based on the CAD/CAE/CAM/HSM technology, this dissertation studies the deformation rules when high-speed milling low-rigidity aluminum workpiece and the means of controlling the deformation from the point of parts' structure, cutting tool selection, workpiece clamping and cutting data,useing theory analysis combined with numeric simulation, and experiment validate.First of all, an orthogonal experiment been conducted to get the force data of 3A21 aluminum parts. Then had a regression analysis of force data using the EXCEL software to establish the 3A21 regression model of cutting force. Secondly, the rules of parts deformation and tool deformation were studied respectively through ANSYS software. How and in what ways the part's thickness and highness affect the machining deformation were also been investigated. After the rule between cutting data and tool deformation been discussed by single-element means, the total machining deformation was calculated by plus the tool and part deformation. Then doing the experiment again to test the verity of numeric simulation result and provide basis for forecasting the process precision and numerical programming.At last, taking a typical workpiece for example, analysed the process difficulty when using three-axial CNC to machine the workpiece, choosed the cutting tool, and??died the interference between workpiece and cutting tool. Then a two-way-tilt clamping approach was bringed up to solve the interference problem. In addition, the fixture was designed according to the clamping approach. The feasibility of clamping approach was verfied by simulating the machining process using UG/CAM software.