Research On Machining Deformation Control And Process Optimization In High Speed Milling Of Thin-Wall Component

Thin-wall component is one of the aerospace typical parts, which is widelyused. Its structure is common complexity, the requirement of machining accuracyand assembly accuracy is very high. Due to its low rigidity, thin-wall structure iseasy to present the problem of machining deformation and tool life short,affected by cutting force and cutting temperature. The traditional manufacturingprocess can’t meet the using requirements for thin-wall component, machiningaccuracy and efficiency is difficult to meet the technological requirements.Therefore, the prediction and control of Thin-wall component machiningdeformation has the important theoretical significance and industrial applicationvalue. The paper is based on “High-speed multi-axis cutting processingtechnology of aviation aerospace typical parts” and “Construction of ComplexNC tool innovation ability platform”, which took TC4titanium alloy as researchsubject. In this paper, a method combined theory modeling, experimentalresearch and finite element analysis was adopted. The main research worksinclude:1. The single factor cutting test of TC4titanium alloy thin-walled componentwas done to find clearly the influence of cutting speed, feed rate, axial and radialcutting depth on cutting force effect.2. Based on the single factor cutting test, The orthogonal test was done. Thecutting force regression equation was established according to the collected datain the test and to simplify the method and linear regression analysis through thematrix. And the cutting force experience model of the TC4titanium alloy thin-wall components was built.3. Combined with the experience model of cutting force, a finite element model of milling thin-wall titanium alloy component was established withsoftware Ansys. And the deformation rules of machining thin-wall titanium alloywas got by analyzing the simulation results. Compared the real data with thesimulation results, the effectiveness of deformation prediction method based onfinite element was verified. It could be a basis for further research of rules inmachining thin-wall components.4. Based on the existing research results, combined with test research and theresults of finite element simulation analysis, this paper discussed the method ofmachining deformation control, some machining references were offered for highefficiency, high quality and low consumption of TC4titanium alloy thin-walledcomponent.