Machining Distortion Analysis And Simulation On The Right End Cap In Transmission System

In the high power density military vehicle driveline, some parts are designed withthin-wall due to space constraints and special requirements, and their machiningprocesses are of high precision. In the machining process, work pieces are so sensitive onthe cutting force, cutting parameters, vibration, and clamping methods that they are veryeasy to distort. In this paper, the typically weak stiffness right end cap in the transmissionsystem is taken as the main object of study. Spigot turning, as the key processes of theright end cap turning, was conducted research. By learning the existing deformationproblems in Spigot processing, the deformation characteristics and the main factorswhich cause its deformation in processing are analyzed. The study is begin with theanalysis of the influence of cutting parameters on cutting force. The law of thedeformation process caused by cutting force is focused on. By optimizing the cuttingforce model to achieve the purpose of reducing the deformation process.In this paper, theoretical prediction model of turning force is studied by learning theprocess of turning the right end cap. Based on the analysis of metal cutting mechanism,both analytical model and empirical formula to forecast cutting force are learned.Empirical model for cutting force was established by organizing cutting force orthogonalregression test on ZG32MnMo bar.Based on the large deformation theory, elastic-plastic finite element model of theturning process was established. According to the mechanical properties of ZG32MnMo,material model in finite element analysis was defined. Using this model, atwo-dimensional finite element simulation of orthogonal cutting of the right end cap wasestablished. The morphology of chip formation process, variation of cutting force changewith cutting parameters was achieved and the validity of the material model was provedto be correct.By analyzing the mechanical model of the right end cap, the radial and tangentialforces were certificated as the main factors affecting the machining distortion.Three-dimensional finite element simulation model consistent with the actual turningconditions was established. Based on this model, the turning process was simulated by using five set of cutting parameters. The deformation of the right end cap turned out to belarger than larger as the cutting force increased. The result shows that machiningdistortion can be reduced by trying to reduce the cutting forces.Finally, in order to achieve the purpose of reducing the deformation process,optimization model of cutting force was established. Experience cutting force modelwhich influences the processing of deformation was taken as the optimization target.Cutting parameters, processing efficiency, surface roughness and power of tools weretaken as constraints. The optimization of cutting parameters was obtained by using thegenetic algorithm optimization tool which is integrated in the Isight software.The optimization of cutting process parameters provides a theoretical basis andfoundation for the machining distortion of such weak stiffness parts.