Deformation Simulation And Process Optimization Of Sidewall Milling

In order to achieve the goal of lightweight and high efficiency of the whole part structure,many modern precision parts widely use the complex thin-walled integral structure parts which tend to be more accurate.This kind of parts has complex structure,poor processing performance,mainly composed of side wall,web and irregular frame.Under the influence of cutting force,cutting heat,clamping environment,vibration and other factors,the whole thin-walled parts have a certain degree of processing deformation,in which the side wall under the influence of cutting force is prone to elastic deformation,resulting in the actual size out of tolerance and other problems.In this paper,the problem of elastic deformation in the milling process of the side wall of the integral structural part of 7050-T7451 is studied.The theoretical model of the milling force of the spiral edge is built and analyzed.The geometric model of the spiral flat end milling cutter is completed by using the mechanical professional software Solidworks.The numerical simulation of the milling process is carried out by using the finite element analysis method and based on the abaqus6.12 finite element software.In order to reduce the elastic deformation of the thin side wall in the milling process,the milling parameters and the geometric parameters of the cutter(diameter and number of teeth)are respectively analyzed In the aspect of parameter optimization,process optimization is carried out from two aspects of tool path and clamping auxiliary support.The optimal parameter combination and process content are obtained through reasonable test methods and data analysis means to reduce milling deformation.The main research contents and achievements of this paper are as follows:(1)Building the finite element simulation model of milling deformation for thin-walled parts.Based on the principle of metal cutting,the deformation mechanism of thin-walled parts is analyzed,and the theoretical model of milling force of spiral edge is constructed.After analyzing the structural characteristics of the spiral flat end milling cutter,the three-dimensional model of the cutter is built with the help of the mechanical software Solidworks.Based on the finite element analysis method and the analysis and application of the key technologies of milling finite element simulation,the simulation model of milling thermal coupling deformation of thin-walled parts based on abaqus6.12 finite element software is established.(2)Research on deformation simulation and parameter optimization of sidewall milling.In order to verify the key technology settings in the model,two-dimensional cutting simulation test is carried out.In order to reduce the elastic deformation of the sidewall in the milling process,from the point of view of reducing the machining deformation,the single factor simulation test and the three-level four factor orthogonal test are used to study the optimization of the sidewall milling parameters(milling depth,milling width,feed rate,spindle speed)and the cutter parameters(number of teeth,diameter).Based on the experimental data,the influence rule of each parameter on the elastic deformation of milling is obtained,and the optimal parameter combination of milling side wall is determined by the intuitive range analysis method.(3)Research on optimization of tool path.From the point of view of optimizing the tool path,this paper uses the finite element numerical simulation method to simulate and study three kinds of tool path sequences: layered up and down,layered symmetry and layered stepped symmetry,and obtains the influence rule of each tool path on the side wall milling deformation and the tool path which can control the elastic deformation more effectively.(4)Research on the optimization of clamping auxiliary support.In order to improve the elastic deformation of sidewall machining,from the point of view of improving the material rigidity of the area to be cut,a three-dimensional elastic non-contact milling auxiliary support finite element optimization model is established to explore the influence of the number of auxiliary support elements,the contact area between the support elements and the workpiece and the layout height of the support contact area on the sidewall milling deformation,The optimal support is obtained.