Research Of Finite Element Simulation Of Thin-wall Parts And The Cutting Parameters Optimization For Virtual Manufacturing

With the further development of equipment manufacturing, virtual manufacturing hasbeen widely used in the actual production and demonstrated its unique advantages. Virtualsimulation and optimization are common forms of the present stage in application of virtualmanufacturing, through the study of the simulation analysis of practical problems, and thenoptimize the influencing factors, this can greatly improves the efficiency of research anddevelopment design, better guidance for actual production. In the engine industry the demandof lightweight is very heavy, with the wide use of high strength aluminum alloy, especially theapplication of some of the thin-walled effectively satisfy these special requirements.In this paper, from the viewpoint of virtual manufacturing, for a diesel engineturbocharger compressor, high-strength aluminum alloy thin-walled blades are easilydeformed in the actual machining, their surfaces quality are not high, to seek a morereasonable process planning and process parameters, based on the theory of thin-wall partsmilling, analyzes on their deformation mechanism and explore the measures to control thedeformation, and then analyze the cutting force model and evaluation, For a particular bladehigh strength aluminum alloy material, use the finite element method to simulation analysisthe rule of cutting force, use neural network to construct the nonlinear mapping relation ofcutting force, with the using of genetic algorithm to optimize the milling parameters research,to complete the cutting force simulation research and cutting parameters optimization designfor the thin blade virtual manufacturing of high strength aluminum alloy material.Through analyze for the factors influencing the machining deformation of thethin-walled blade, find that the main influence factor is the cutting force, after the analysis andevaluation of a variety of cutting force models, use the method of finite element simulation, chose the material with high strength aluminum alloy2A12to establish a simulation model oforthogonal cutting, analyse its stress, the cutting force change rule, provide the basis andobjective parameter optimization.Based on multi-objective optimization theory, establish the2A12aluminum alloythin-walled milling multi-objective optimization model, for the key factors cutting force ofthin-walled parts deformation, this paper use the neural network to predict the milling force,establish the mapping relationship between the force and processing parameters, then take itas an important part of the optimization index in multi-objective optimization, combine withthe genetic algorithm, use MATLAB programming to realize the multi-objective optimization.By comparison, this multi-objective optimization method for high strength aluminum alloythin-walled, within a certain range can achieve the purpose of reduce the cutting force toimprove efficiency.