Study On Milling Process And Deformationof ZTC4 Titanium Alloy Component

Due to the fact that modern aerospace products should meet such requirements as high strength, high heat resistance and compact structure, casting titanium alloy monolithic components are becoming more and more widely used for those products. However, back-off of the workpiece locality during the machining of the components, the rapid wearing of the tool in machining titanium alloy, the redistribution of the initial residual stress with the removal of materials, all those factors will, finally, lead to the machining deformation of the components. Experiments and finite element simulation are combined to carry out researches on the deformation of the ZTC4 monolithic component from the following three aspects, the back-off of the workpiece caused by the redistribution of initial residual stress,the cutting load and the tool wear. Besides, the deformation control strategies are also put forward. The major research work is as follows:1.The effects of cutting parameters on cutting force and cutting temperature are studied through single factor experiments, and the empirical formula is established. The empirical formula on tool wear with cutting speed, each tooth feed, cutting width is established through the orthogonal test.It shows that the each tooth feed has the most serious influences on tool wear in the researching parameter range.2. By combining the finite element simulation and experiments, the annealing process of the disk part is studied and the finite element simulation model of ZTC4 annealing is established.Based on the model,the annealing process of the component is studied and its initial stress field is established.3.Based on the finite element simulation, the deformation regularity caused by annealing and stress release,cutting load and tool wear are researched and the forecase deformation value by coupling the above factors are obtained.The component machining deformation value is measured by the aid of the three-coordinates measuring machine. The simulation result and the actual result are compared to verify the accuracy of the finite element model.The machining parameters are optimized by using genetic algorithm. The cutting tool compensation method is proposed to reduce the machining deformation. The optimized parameters and compensated path are verified to be able to control deformation by simulation.