Research On Machining Deflection Prediction And Influence Of The Cutting Parameters In Peripheral Milling Thin-walled Component

Thin-walled components have been widely used in modern aerospace industry and shipbuilding industry for its lighter weight and higher strength when compared with other materials under the same condition. Due to the thin-walled property and the low-rigidity of the work piece, significant deflection may be easily caused under the influence of cutting force, even the chatter phenomenon can also be seen during the milling process if some improper cutting parameters are applied, which will influence seriously the accuracy and the surface quality, even lead to useless products. Consequently, investigation on the prediction and control of the deflection errors during the milling process are of great significance to improve the accuracy and the surface quality, make the process more effective and establish the adaptive precision NC(Numerical Control) machining. By using finite element method, NC machining technology and the metal cutting mechanics, the machining deflection predictions of a thin-walled rectangular-plank and an impeller blade, the influence of cutting parameters on machining deflections are studied in this paper. The specific works are as following:1) The finite element deflection prediction models of peripheral-milling a thin-walled rectangular-plank and an impeller blade are established respectively. The machining deflection prediction models are obtained using finite element method after simplifying of the milling process, based on metal cutting mechanics. A thin-walled rectangular-plank and an impeller blade with complex surface are simulated to predict milling deflection as examples. This work sets a foundation for the following researches, the influence of the cutting parameters on work piece's machining deflections, and the experimental analysis.2) The influence of the cutting parameters on the machining deflections of the thin-walled rectangular-plank and the impeller blade is analyzed. A number of groups of cutting parameters are designed. The first group is taken as the standard group, and the other groups are then obtained by changing cutting parameters such as axial depth of cut, feed per tooth, tool diameter, radial depth of cut, spindle speed. Through the compare of work piece's milling deflections, which have been by using foregoing deflection prediction model, the influence of each cutting parameter on the machining deflections is disclosed. This provides preferable reference for the choice of cutting parameters.3) The relationship between the spindle speed and amplitude of vibration of the component during peripheral-milling is investigated. The range of spindle speed for steady milling thin-walled rectangular-plank is gained by FEA modal analysis. This provides a reference for the vibration's suppressing and proper choice of spindle speed.4) Trials for the thin-walled rectangular-plank'NC milling are carried out to verify the prediction results and the influence of cutting parameters on the machining deflections. By making experiments design and on-site measuring, the experimental results are in a preferable agreement with the prediction deflections.In conclusion, this paper provides a preferable deflection prediction method for peripheral milling process with the thin-walled components and significant reference for the milling parameters'optimization.