【摘要】：在航空航天制造過程中,鋁合金是最常用的材料之一。其中,鋁合金預(yù)拉伸板因其重量輕、強度高的優(yōu)勢被大量用于制造框架結(jié)構(gòu)和薄壁結(jié)構(gòu)等。但是在加工過程中,蘊藏在鋁合金預(yù)拉伸板的殘余應(yīng)力隨著外部材料的去除而不斷釋放,打破了原有的平衡狀態(tài),產(chǎn)生了不可避免的加工變形。本文以鋁合金預(yù)拉伸板材為研究對象,借助有限元仿真、切削試驗等研究手段,對板材的殘余應(yīng)力進行評估,獲得了殘余應(yīng)力的分布狀態(tài),并將其輸入到有限元軟件中進行變形預(yù)測。同時對有限元軟件進行二次開發(fā),提高了其物理仿真與變形預(yù)測的計算效率。最終將其應(yīng)用到實體的變形預(yù)測中。主要研究內(nèi)容如下:(1)使用盲孔法與輪廓法對測量了鋁合金預(yù)拉伸板的殘余應(yīng)力。為提高測量準確性,針對輪廓法測量殘余應(yīng)力的特殊要求,通過Plackett-Burman結(jié)合正交試驗方法,揭示了線切割參數(shù)對輪廓法切割質(zhì)量的影響規(guī)律,研究表明,送絲速率、絲張力和峰值電流是影響測量精度的三個主因素。當(dāng)峰值電流為10A、絲張力為20g和送絲速率為180mm/min時切割質(zhì)量為最優(yōu);通過Box-Behnken響應(yīng)面分析法,獲得了表面粗糙度的預(yù)測模型,提高了輪廓法評估殘余應(yīng)力的準確性。(2)對于大尺寸的結(jié)構(gòu)件,使用有限元方法進行加工變形的預(yù)測時效率很低,不易實現(xiàn)全尺寸、完整結(jié)構(gòu)、復(fù)雜切削走刀路徑狀態(tài)下的加工變形準確預(yù)測。為了解決這一問題,基于Abaqus軟件的有限元仿真及其二次開發(fā)技術(shù),本文提出一種采用連續(xù)多個靜態(tài)隱式分析步模擬切削加工過程的加工變形有限元快速仿真方法。開發(fā)了相關(guān)軟件,能夠統(tǒng)一施加殘余應(yīng)力并提取后續(xù)分析的位移、應(yīng)力數(shù)據(jù)。(3)基于測量得到的預(yù)拉伸板殘余應(yīng)力,使用二次開發(fā)的有限元仿真技術(shù)對某型機匣件的加工變形進行了預(yù)測,并將仿真結(jié)果與切削試驗結(jié)果進行對比,獲得了加工變形的特點。
[Abstract]:Aluminum alloy is one of the most commonly used materials in aerospace manufacturing. Because of its light weight and high strength, aluminum alloy pre-stretching plate is widely used in the manufacture of frame structure and thin-walled structure. However, in the process of machining, the residual stress stored in the aluminum alloy pre-stretching plate is released continuously with the removal of external materials, which breaks the original equilibrium state and produces inevitable machining deformation. In this paper, the residual stress of aluminum alloy pre-drawn sheet is evaluated by means of finite element simulation and cutting test, and the distribution of residual stress is obtained. It is inputted into the finite element software for deformation prediction. At the same time, the secondary development of finite element software improves the calculation efficiency of physical simulation and deformation prediction. Finally, it is applied to the deformation prediction of solid. The main contents are as follows: (1) the residual stress of aluminum alloy pretension plate was measured by blind hole method and profile method. In order to improve the accuracy of measurement, according to the special requirement of measuring residual stress by contour method, the influence of wire cutting parameters on the cutting quality of profile method is revealed by means of Plackett-Burman combined with orthogonal test method. The research shows that wire feeding rate, Wire tension and peak current are the three main factors affecting the measurement accuracy. When the peak current is 10A, the wire tension is 20g and the feeding rate is 180mm/min, the cutting quality is the best. By means of Box-Behnken response surface analysis, the prediction model of surface roughness is obtained, which improves the accuracy of profile method in evaluating residual stress. (2) for large-size structural parts, the prediction model of surface roughness is obtained. When using finite element method to predict machining deformation, the efficiency is very low, and it is not easy to realize full-size, complete structure and accurate prediction of machining deformation under the condition of complicated cutting path. In order to solve this problem, based on the finite element simulation of Abaqus software and its secondary development technology, this paper presents a fast finite element simulation method of machining deformation using continuous static implicit analysis steps to simulate the machining process. Relevant software has been developed, which can uniformly apply residual stress and extract displacement and stress data from subsequent analysis. (3) based on the measured residual stress of pre-drawn plate, The machining deformation of a machine box is predicted by using the secondary developed finite element simulation technology, and the characteristics of the machining deformation are obtained by comparing the simulation results with the results of the cutting test.
【學(xué)位授予單位】：沈陽航空航天大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG146.21

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