Simulation And Parameter Optimization Of CFRP Milling Process Based On Deform And Experimental Study

The density of CFRP is smaller than steel,and it has high specific modulus,high specific strength,good corrosion resistance,anti-fatigue ability,vibration reduction and design ability is better than traditional materials and can be widely applied in aerospace,military,medical and other fields of automobile.However,due to the lack of CFRP processing knowledge,resulting in fewer varieties of CFRP products on the market and the quality is not well.So,studying the processing methods of CFRP by taking of new methods,and enriching the related processing knowledge of CFRP are of strategic significance to apply CFRP to a wide range of scientific research and production.In this dissertation,carbon fiber composite material is studied and based on the CFRP related cutting mechanism and finite element analysis theory,build the 3D milling model by using the process simulation software Deform.Using single factor method to simulate the CFRP milling condition under different milling parameters and analysis of the milling force,milling temperature,surface stress,tool wear and the machining quality.Using multi objective optimization software Isight to make the multi-objective optimization.Finally,the CFRP milling experiments are carried out on the basis of the simulation parameters and optimization parameters and compared with the simulation results,proved the reliability of simulation and optimization.It is proved that the numerical simulation method is feasible to study the milling of materials.The main research contents and results are as follows.1.Discussing the material properties,cutting mechanism and machining defects of CFRP.Studying the factors that affect the cutting force and the modeling theory of finite element analysis and the key technology of finite element modeling about CFRP and laying the theoretical foundation for finite element analysis software.2.To establish the constitutive model of CFRP and the three-dimensional finite element milling model,and the dynamic milling process is simulated by Deform.Changing the spindle speed n,feed rate f and cutting depth pa,the radial cutting depth ea and cutting tool material by using the single factor method.The effects of various factors on milling force in three directions of X,Y and Z,milling temperature,surface stress,tool wear and machining quality were analyzed and get the results: When using PCD tool,high speed,low feed,higher cutting depth and larger radial cutting depth,the milling force,milling temperature,surface stress is low,and can get small tools wear,good machining quality and high efficiency.3.Using multi objective optimization software Isight to optimize the parameters,The original design variables are spindle speed n,feed rate f and cutting depth pa,the radial cutting depth ea.Using the orthogonal design to design the experiment and collecting enough samples.Using the response surface method to establish the approximate model and the interaction analysis is performed on the response surface model.The main effect of design variables on response model is analyzed.Finally,the accuracy analysis and error analysis of response surface model show qualified.Doing multi objective optimization of design variables by using AMGA archive genetic algorithm and find the perfect result and the milling force yF,zF and milling temperature T decreased,and the purpose of optimization was achieved.4.Doing the same conditions milling experiments on the machining center,Observe surface morphology of samples by using VHC-1000 C type super depth of field microscope and the results of finite element simulation are compared with milling experiment.The results show that the agreement between the observed results and the finite element simulation results is higher.The milling experiment is carried out according to the optimization scheme and observe the surface morphology,compare the results of finite element simulation with milling experiment and analyzed and the result show that the surface quality of CFRP is improved by using the optimized scheme.Finally get the results: The milling finite element model of CFRP has high reliability and the result of parameter optimization is feasible.It is proved that the milling finite element simulation method is feasible and it has certain reference significance to the production practice.