The Research On The Effect Of High Speed Milling And Vibration On Deformation Of The Aluminum Alloy Edge Beam

The Aluminum Alloy edge beam is the longitudinal beam located on the both sides of the underframe of the EMU,and it can support the load of the carbody and connect the underframe and the side wall,so that it is one of the key components to ensure the safety of railway train operation.Due to the complex structure,poor rigidity of the workpiece,it is not easy to clip and process,Aluminum Alloy edge beam can prone to deformation and crack phenomenon in the high speed milling process,so the result shows that the qualified rate of side beam is low,and which the economic loss is causedIn this paper,the edge beam of aluminum alloy is taken as the research object,and carries out research on the deformation of the workpiece in high speed milling and vibration by the milling process,the main research contents are as follows:First,by comparing three classical milling force models,an empirical model for cutting force of Aluminum Alloy edge beam is established,the 16 sets orthogonal test of milling parameters was designed and completed,and the milling force was acquired by using YDX-III9702 three direction piezoelectric milling measuring instrument on VMC850 L machining center,and the regression analysis of milling force data is carried out by EXCEL,the empirical formula of milling force of Aluminum Alloy edge beam is obtained,verified the validity of the model prediction and the measured value,the average error is below 6%,Therefore,the model has high reliability,and which it provides support for the optimization of finite element boundary conditions and the optimization of milling parameters.Secondly,Aluminum Alloy edge beam modal and harmonic response analysis.The model of Aluminum Alloy side beam is established by UG,and the natural frequencies and modes of the 20 order are obtained by modal analysis with ANSYS,the largest is239.31 Hz,the smallest is 75.508 Hz,and the maximum deformation is 0.667 mm at the fourteenth order 218.18 Hz.So we can based on the modal analysis results,the harmonic response analysis is carried out under different milling forces,and resonance occurs at180 Hz and 240 Hz,meanwhile,the frequency of the resonance is independent of the milling force,but the greater the milling force,the greater the amplitude(deformation).This result can provide a reference for the selection of milling parameters.Finally,studying of milling parameters and milling force and milling parametersand machining vibration relationship through the experiment,the influence of milling parameters on milling deformation is obtained,and the optimal milling parameters are obtained by test and ANSYS analysis and verification.