Alloy The Weak Stiffness Components Of High-speed Milling Technology Research

Because of the thin-walled aluminum alloy workpieces having many excellent properties such as light weight, high strength, good thermal conductivity.it is widely used in the filed of aviation and astronautics, communication, automotive manufacturing and such other realms.But they are easy to deform in the machining process which is caused by complex structure and low rigidity, and so they can't satisfy the machining require of accuracy and surface quality.High-speed machining technology has performanced special superiority in the machining of complicated thin-walled workpieces because of higher production efficiency,higher surface quality and higher machining accuracy.Though the research of high-speed machining technology has been widely carried out in recent years,it still exists many problems in practical application and needs further research in the material removal mechanism of high-speed machining,the basic thoery of processing method of high-speed machining and the cutting databases.This paper researches on the high-speed machining technology of complex thin-walled aluminum alloy workpieces in the aspects of milling force,the surface roughness and machining deformation and prediction of deformation.The research of the high-speed machining technology about complex thin-walled aluminum alloy workpieces bases on the technology of CAD/CAM/CAE,and uses combining methods of theoretical analysis, finite element simulation and test analysis.The effect law of cutting parameters to surface roughness and the important effect factors of surface roughness are researched through the single factor cutting experiment of the high-speed machining. The prediction model of the surface roughness is established by using orthogonal test method and is tested by the method of testing significance.Based on the analysis of the high-speed cutting mechanism, the source of milling force and the modeling theory of milling force,the effect law of cutting parameters to milling force is researched through the single factor cutting experiment of the high-speed machining.The prediction model of milling force and is established by analytical model,compiling corresponding program and using test method.And then,basing the guarantee of cutting efficiency and the optimization of milling force,the select principle of cutting parameters is studied.The paper makes theoretical analysis about the reason of the machining, deformation of typical weak rigidity structures,and combing the research result of milling force, the finite-element sofeware and the equivalent discrete technology of loading,the rules of machining deformation of thin-wall pieces are worked out.Combining the test results, the work of optimuming the cutting parameters of thin-wall pieces is studied and finished.Finally,combining with the research result about the cutting force,the surface roughness and the forecast and control of machining deformation of the aluminum alloy high-speed milling,and using the methods of optimuming cutting parameters,the choice of the tool,the clamping fixtures and the tool path,some machining exprements of typical thin-walled aluminum alloy structure which is weak rigidity and thin-walled are finisned.The machining scheme that can satisfy the mass,higher accuracy and low cost machining of radar parts is worked out,and this thoery and method could provide good reference for other machining of similar aluminium alloy weak rigidity woekpieces.