Study On Deformation Prediction And Error Compensation Technology Of Thin-walled Part In Five-axis Milling

The thin-walled curved parts represented by aero-engine blades have the characteristics of complex shape,easy deformation and high machining precision.In order to reduce the processing error and reduce the production cost of parts,this paper takes the whole impeller blade as the research object.The elastic deformation prediction and error compensation method of blade in five-axis milling process are deeply studied and discussed.This paper focuses on the following aspects:(1)Based on the UG virtual machining module,the non-interference tool track file of blade five-axis milling is generated,and the tool axis vector is optimized under the constraint of swing angular velocity.It provides data support for the calculation of three-way milling force and finite element deformation prediction of ball end milling cutter.(2)Combining the geometric characteristics of thin-walled surfaces with the change of tool pose during machining,a solution method for cutting-in cutting edges suitable for five-axis surface milling is proposed.The instantaneous milling force model of the ball-end milling cutter was established by the analytical method.Finally,according to the simulation results of the milling force,the cutting situation of the milling cutter is analyzed and the validity of the mechanical model is verified.(3)Based on the secondary development of ABAQUS,the finite element simulation process of five-axis milling of blades was completed,and the process of milling force loading and workpiece material "removal" along the tool path was realized by establishing the tool position point cycle and combining the "unit life and death" technology.Predict the deformation of the selected blade nodes,and analyze the blade milling deformation law according to the simulation results.(4)The iterative compensation model of deformation error is established by mirror compensation and surface reconstruction technology,which reduces the influence of milling elastic deformation on blade machining accuracy.Finally,use the RSG dialog box builder of ABAQUS to complete the development of the simulation interactive plug-in,which improves the efficiency of finite element simulation pre-processing and post-processing.