The Large Screw Whirlwind Milling Process Optimization Studies

Hard whirling is a new manufacturing method which is discovered by the middle of 20 century. It is famous for its high quality, high efficiency, low-consuming, clearness, and has been intensively used in screw and ball screw manufacturing. In this article, we aim at improve the machining accuracy of large ball screw. Meanwhile, we use theoretical modeling and finite element analysis to optimize the manufacturing process.Firstly, in order to increase the rigidity of large ball screw, we build the dynamic equation of large ball screw under supports, taking consider of rotating speed and gravity of large ball screw, and use Genetic Algorithm toolbox in MATLAB and Finite element analysis to optimize the layout of supports.Secondly, do research about the method to optimizing manufacturing process which is called optimization algorithm. Because Particle Swarm Optimization algorithm has fast convergence efficiency, simple procedure, little subject involved and so on, so in this article we are mainly focus on it, what's more, we improve the performance of Particle Swarm Optimization algorithm through adding Random Direction Method into it, and we use RDM-PSO to optimize the layout of supports again.Thirdly, modeling the minimum chip thickness, the instantaneous chip thickness and tool-work contact length, and theoretically build the whirling force model according to high speed metal cutting theory, meanwhile study whirling force, surface residual force, chip shape under different whirling condition and the structure of cutter through metal cutting simulation in ABAQUS.Fourthly, build the dynamic equation of rotating large ball screw under axially moving interrupted whirling force, solving this equation and doing dynamic modal analysis of large ball screw under whirling in ABAQUS to get ball screw's deflection, taking consider of the rotating speed and gravity of ball screw, axially moving interrupted whirling force and clamping force.Finally, we consider the deflection of ball screw under axially moving interrupted whirling force as objection function, and use RDM-PSO and GATO to optimize the whirling parameter.