Thin-walled Parts Machining Process Of Numerical Simulation And Deformation Prediction Research

Because of its outstanding features like light weight and high strength, thin-walledworkpieces have been widely applied in various industrial fields. However, due to thelow stiffness of thin-walled workpieces and the high frequency of material removalduring the processing, thin-walled workpieces can be easily deformed under the cuttingforce, and furthermore, the accuracy and quality of thin-walled workpieces would bealso deeply affected. Therefore, exploring the rational processing method and theeffective control for the after processing deformation is significant important to China’smanufacturing industry.This paper focuses on thin-walled workpieces in the front of nozzles by the finiteelement analysis approach. The study is aimed at the constitutive models, which arenot able to accurately describe the dynamic performance of the material. The amendedJohnson-Cook constitutive mode would be embedded in the software platform throughVUMAT User Subroutine by ABAQUS. Moreover, the precision of VUMAT UserSubroutine can be verified according to the numerical simulation of two-dimensionalcutting.Based on the User Subroutine, a three-dimensional numerical simulation was builtfor the cutting process of the nozzle with explicit dynamic finite element method.This simulation reveals the law of deformation affected by the cutting parametersduring the nozzle processing. Furthermore, the study also contrasts the predictedphysical quantities such as the equivalent strain, the cutting force and the stress by theamended Johnson-Cook constitutive model with those by the original one. The resultsindicate that the modified Johnson-Cook constitutive model is more suitable for thethin-walled workpieces during the cutting process.In order to improve simulation efficiency, the researcher also detailed studied thesecondary development of ABAQUS and successfully achieved the platformdevelopment for rapid processing and simulation of thin-walled workpieces. Thisdevelopment platform includes some functional modules like parametric modeling,automatic clamping and submitting the input and output files, and in the meantime provides a very friendly GUI interface.