Machining Simulation And Experimental Study On Milling Process Of Aluminum-alloy Thin-walled Components

Thin-walled aluminum is a very important part of aviation industry, but because of the thin presence, it will be result in lower stiffness during the milling process. The thin-walled portion is easily deformed, using conventional milling. It is difficult to ensure surface quality of the thin-walled parts. In this paper, a theoretical model of the thin-walled aluminum milling force in the milling process and simulation analysis was practiced. The modal of thin-walled aluminum was simulated with ANSYS finite element analysis software. Then the results of milling force simulation were used to analyze harmonic response of aluminum alloy thin-walled parts. Finally, the theoretical model of milling force experiments were verified and corrected, and the experimental results were combined with modal analysis and harmonic response analysis to summarize the optimization of parameters for milling thin-walled aluminum. These were used to guide the actual milling.First, on the basis of the classical theory of milling force, the existing theoretical models were improved for the milling force, considering the size of the deformation important implications chip thickness and effective rake angle of milling force. Using Matlab to simulate the improved milling force model, the experimental the validation and correction were practiced for the improved milling force model by experiment.Secondly, in this paper the use of ANSYS finite element analysis software was used to simulate the modal analysis for the thin-walled aluminum, and on the basis of the modal analysis, the harmonic analysis was carried out. Natural frequency can be obtained for the thin-walled aluminum alloy according to results of the analysis, at the same time harmonic response under the milling force of thin-walled aluminum alloy thin-walled parts can be obtained. This can help to guide the milling machine operator for selecting milling parameters.Finally, the effect of milling parameters on the surface quality of aluminum alloy thin-walled parts were studied by the orthogonal experiment and the modal and harmonic response analysis of the thin-walled aluminum parts. The optimization of milling parameters for the thin-walled aluminum parts on the milling process was obtained. Comparing the experimental data to the simulation analysis results, the experimental results and the simulation results are very close from the experimental data. This indicated that the use of ANSYS finite element analysis can be well used to predict the deformation of thin-walled aluminum alloy. The studied results were practical significance for the milling processing of the thin-walled aluminum.