| The deformation of aeronautical thin-wall components due to NC machining is the main factors influencing machining precision and quality in aviation manufacturing technologies, and this problem seriously hinder the development of the aviation industry. So it has great academic and engineering value for the prediction and improvement of aeronautical thin-wall components machining deformation. In view of this complex problem, a method based on experiments and computer analysis is adopted in this dissertation.The widely used method of identifying the cutting parameters in engineering is verified through milling experiment by means of regression-orthogonal approach with four factors. The deformation in milling process of typical thin-wall workpieces is studied, and according to finite element method and the theory of cantilever, the numerical method used to calculate the deformation of tool and workpiece is developed. The cutting coefficient is accurately confirmed through classifying milling area in milling process. For modeling the variation of milling force in reality, the milling forces are loaded nonlinearly on the workpiece based on FORTRAN subroutine of ABAQUS. Considering the influence of deformation of tool and workpiece in the milling model, the flexible model is developed for the accurate prediction of milling deformation and the valuable conclusions of deformation in milling process is acquired from the model. Based on the magnitude and contour of deformation, the compensation is implemented on the cutting parameters through rectifying the NC programming and it provides references for thin-wall milling process. The analysis system of deformation is developed and it has good capability in other geometry model.Many machining experiments are arranged for the typical thin-wall components using the proposed modified cutting parameter obtained by the theory analysis and numerical simulation, and the effectiveness of the presented compensation method is validated. |
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