Study On Precise Effective Cutting Mechanism Of Titanium Alloy Thin-Walled Parts

With the development of aerospace industry, the materials performance have been more and more important. The requirement of titanium alloy thin-walled parts is also constantly increasing. However, due to the structural characteristics of thin-walled parts, the parts are low stiffness and high yield ratio, and in the cutting process, cutting force and cutting heat easily lead to cutting deformation, so it is more difficult to ensure the machining accuracy and requirements by the traditional processing methods. In this paper, titanium alloy thin-walled parts are experimented and simulation researched by the precision machining methods, and the influence of cutting deformation induced by cutting parameter and residual stress is analyzed.Firstly, to cut titanium alloy material precisely, and get better surface quality and control the deformation, the cutting force and tool wear must be effectively controlled, in particular, the choice of tool material is reasonable. A single factor comparison test of cutting parameter is carried out on carbide tools, PCBN tools and diamond tool. The factors influencing on cutting force and surface quality are analyzed, and the cutting mechanism of diamond tool machining titanium alloy is researched by the experiment.Secondly, the deformation factors of thin-walled parts and residual stress are analyzed. By calculating cutting force and cutting temperature in the shear area, flank wear area and cutting edge area and residual stress, the influence of cutting deformation induced by residual stress is analyzed , and the cutting deformation theory model is established.Thirdly, the machining process is analyzed by finite element method. The model of machining is refined and improved due to the using of Johnson-Cook material model and the shear model. By single factor cutting simulation of cutting parameter, further study is carried out on the influence of cutting deformation and residual stress induced by cutting Parameters selected.Finally, by precision cutting methods, study is carried out on cutting titanium alloy thin-walled parts cut by diamond tools. The cutting parameters are analyzed and optimized to reduce residual stress and improve removal rate. By testing, finite element model is testified, and precision cutting mechanism of titanium alloy thin-walled parts is obtained. The useful reference data is provided to control cutting deformation of thin-walled parts.