Deformation Prediction For Milling Process Of Thin-Walled Parts

There are often some poor rigidity and high precision thin-walled parts in electromechanical products, especially in aeronautic products. Most of them are key parts of products. The characteristics of these parts are general as follows: complex structure, thin-walled, variable thickness, many surface and curve structures, high reconciliation precision, etc. At present, method of NC milling has been used to process these parts. But deformation is easy to appear because of poor rigidity reason in processing. So it's difficulty to control machining accuracy and efficiency. Based on reviewing research status of machining deformation of thin-walled part at home and broad, finite element numerical simulation technique are systematically studied to simulate milling process in order to predict deformation of thin-walled part caused by cutting force. Efforts are focused on the milling process mechanical modeling of thin-walled part and the deformation prediction for milling process with finite element and ANSYS analysis.This paper presents research status of machining deformation of thin-walled part and cutting deformation mechanism and summarizes reasons of machining deformation of thin-walled part. By analyzing numerical simulation of machining deformation of thin-walled part, conclusion can be made that cutting force model and finite element model are the research key of machining deformation of thin-walled part. It has important significance for studying on them.The main work is focused on using matrix simplified method to establish empirical model of milling force of 7075-T651 aluminum alloy material on the basis of given mathematical formula of parameter and index. Orthogonal test of four factors and four levels is used in milling experiment. Effectiveness of empirical model of milling force has been verified by this milling experiment.Finally, ANSYS are used to analyze deformation of thin-walled part in milling process. Thin-walled parts of frame body and complex surface blade are analyzed by finite element method to obtain basic law and put forward deformation control measure. It provides a fundamental basis for increasing productivity and deformation control of milling.This research belongs to applied basic research. It has potential application value in numerical simulation. In improving machining precision, reducing production cost and improving machining efficiency, it has important economic benefit.