Experimental Study And Milling Parameters Optimization In Milling Process Of6061Alunminum Alloy Thin Wall Workpiece

Cubing is a Car model which is made by machining in accordance withthe real car. The cubing can be used in the dimensional inspection of interiorsand exteriors and the assembly checking of spare and accessory parts. It canfind and revise the design defects. And it can significantly shorten thedevelopment cycle of new products, reduce development costs and improvedevelopment quality. So the cubing plays an extremely vital role in designprocess, product verification process, new project start-up and massproduction process.The machining parameters’ selecting and cutting vibration, which ismade by the milling of engine cover module, has been researched.First, an orthogonal experiment scheme was adopted to investigateball-end milling force. Orthogonal regression analysis method was used tobuild the ball-end milling force experience formula, and the significance testwas finished. At last milling experiment was applied to test and verify theaccuracy of formula and analyze the correlation of milling force and millingparameters.Second, the part-fixture finite element model (the sample and enginecover module) was built. The displacement boundary conditions of thepart–fixture finite element model (the sample and engine cover module) andforce boundary condition were analyzed, based on e ball-end milling forceexperience formula and experiment. The three methods were used in FEManalysis. It includes Modal analysis, static analysis and instantaneousdynamic analysis. And the experiments was used to verify the accuracy ofFEAThird, the relationship between Milling parameters and vibration amplitude was researched based on the vibration testing. At last millingparameters of key points of milling was optimally selected based on MRR,Machining deformation, milling force and vibration amplitude. And theCorrectness of optimal selection is verified by FEM...