本文選題：薄壁件 + 加工變形　； 參考：《西南交通大學(xué)》2016年碩士論文

【摘要】：隨著制造業(yè)的發(fā)展,傳統(tǒng)的加工方式已難于滿(mǎn)足工業(yè)的需求。高速切削(High Speed Cutting, HSC)加工技術(shù)應(yīng)運(yùn)而生,高速加工技術(shù)采用超硬材料刀具和磨具,利用高精度、高自動(dòng)化和高柔性的制造設(shè)備,以實(shí)現(xiàn)提高切削速度來(lái)達(dá)到提高加工效率和加工質(zhì)量,降低加工成本的目標(biāo)。在航空、航天中高速切削加工技術(shù)已得到廣泛的應(yīng)用。但是航空、航天產(chǎn)品中多采用質(zhì)量較輕的鋁合金薄壁零件,在高速加工中極易出現(xiàn)振動(dòng)現(xiàn)象,導(dǎo)致工件加工變形增大,難以滿(mǎn)足加工要求。因此需要在加工前基于加工參數(shù)對(duì)工件的加工變形情況進(jìn)行預(yù)測(cè),優(yōu)化加工參數(shù),以提高加工質(zhì)量和成品率。然而,實(shí)現(xiàn)鋁合金薄壁零件的加工變形預(yù)測(cè),存在以下幾個(gè)難點(diǎn)：(1)基于切削參數(shù)的動(dòng)態(tài)銑削力模型的構(gòu)建,(2)動(dòng)態(tài)切削力作用下的加工系統(tǒng)動(dòng)力學(xué)模型的構(gòu)建及系統(tǒng)動(dòng)力學(xué)行為預(yù)測(cè),(3)動(dòng)態(tài)切削力作用下的薄壁件加工變形預(yù)測(cè)模型的構(gòu)建。為解決這些問(wèn)題,本文以懸臂板結(jié)構(gòu)的典型薄壁件為研究對(duì)象,對(duì)薄壁件高速加工工藝系統(tǒng)進(jìn)行了模態(tài)分析、銑削力建模、加工系統(tǒng)動(dòng)力學(xué)建模及振動(dòng)特性分析、加工變形預(yù)測(cè)建模等方面的研究。其主要內(nèi)容包括以下幾個(gè)方面：(1)通過(guò)分析薄壁件銑削加工工藝系統(tǒng)的特點(diǎn),機(jī)床的剛度相對(duì)于工件和刀具較高,因此將加工工藝系統(tǒng)簡(jiǎn)化為工件子系統(tǒng)和刀具子系統(tǒng)。分別對(duì)工件子系統(tǒng)和刀具子系統(tǒng)進(jìn)行模態(tài)分析,獲取加工工藝系統(tǒng)振型最突出的平面,以及在該平面內(nèi)的模態(tài)質(zhì)量、模態(tài)阻尼和模態(tài)剛度等模態(tài)參數(shù),為后續(xù)薄壁件加工系統(tǒng)動(dòng)力學(xué)模型的構(gòu)建提供基礎(chǔ)。(2)提出了一種動(dòng)態(tài)切削力建模方法,首先通過(guò)分析銑削機(jī)理,將切削刃的切削過(guò)程細(xì)分為切入、穩(wěn)定和切出三個(gè)時(shí)間段,分別建立不同時(shí)間段切削刃的微元切削力模型,再通過(guò)分析某一瞬時(shí)參與銑削的單齒切削刃長(zhǎng)度,將該長(zhǎng)度上的所有微元切削力進(jìn)行積分,并計(jì)算該時(shí)刻參與切削的銑刀的齒數(shù),將所有刀齒上的切削力求和,從而建立整個(gè)刀具的動(dòng)態(tài)切削力模型,然后通過(guò)銑削力、刀具和工件的振動(dòng)位移關(guān)系,建立基于動(dòng)態(tài)位移的銑削力模型,最后通過(guò)試驗(yàn)驗(yàn)證了該方法的正確性。(3)基于系統(tǒng)模態(tài)分析和動(dòng)態(tài)切削力模型,通過(guò)分析銑削力與加工工藝系統(tǒng)振動(dòng)的關(guān)系,構(gòu)建了薄壁件側(cè)壁加工工藝系統(tǒng)的動(dòng)力學(xué)模型,用于分析加工系統(tǒng)的動(dòng)力學(xué)特性,并基于該模型提出了一種薄壁件銑削加工顫振穩(wěn)定性的預(yù)測(cè)方法,該方法采用銑削穩(wěn)定性葉瓣圖來(lái)判斷不同切削參數(shù)條件下加工的穩(wěn)定性,最后通過(guò)試驗(yàn)驗(yàn)證了模型和方法的正確性。(4)基于動(dòng)態(tài)銑削力模型和顫振穩(wěn)定性預(yù)測(cè)方法,構(gòu)建了薄壁件加工變形預(yù)測(cè)有限元模型,實(shí)現(xiàn)了薄壁件加工前的變形預(yù)測(cè),從而為薄壁件銑削加工工藝參數(shù)的優(yōu)選提供支持,最后通過(guò)試驗(yàn)驗(yàn)證了該模型的正確性,并利用試驗(yàn)分析了薄壁件在加工過(guò)程中出現(xiàn)振動(dòng)對(duì)加工變形的影響。通過(guò)上述四個(gè)方面對(duì)薄壁件加工過(guò)程進(jìn)行的研究,建立一套完整的針對(duì)薄壁件加工變形預(yù)測(cè)的系統(tǒng)性方法,為提高薄壁件加工的生產(chǎn)率和產(chǎn)品的合格率,以及加工工藝參數(shù)的優(yōu)化選擇提供了具有指導(dǎo)意義的方法和結(jié)論。
[Abstract]:With the development of the manufacturing industry, the traditional processing methods have been difficult to meet the needs of the industry. High Speed Cutting (HSC) processing technology came into being. The high speed machining technology adopts super hard material tools and grinding tools, high precision, high automation and high flexible manufacturing equipment to improve the cutting speed to improve the processing efficiency. The target of rate and processing quality and reducing the cost of processing. In aerospace, high speed machining technology has been widely used in aerospace. However, aviation and aerospace products are mostly lightweight aluminum alloy thin-walled parts. The vibration phenomenon is easy to appear in high speed machining, which causes the deformation of workpiece to be increased, so it is difficult to meet the processing requirements. Therefore, it is difficult to meet the requirements of processing. It is necessary to predict the machining deformation of the workpiece on the basis of processing parameters and optimize the processing parameters to improve the processing quality and yield. However, there are several difficulties in the prediction of machining deformation of aluminum alloy thin-walled parts. (1) construction of dynamic milling force model based on cutting parameters, (2) dynamic cutting force The construction of the dynamic model of the machining system and the prediction of the dynamic behavior of the system. (3) the construction of the deformation prediction model of the thin-walled parts under the action of dynamic cutting force. In order to solve these problems, this paper takes the typical thin-walled parts of the cantilever plate structure as the research object, and carries out the modal analysis, the milling force modeling and the addition of the thin wall parts. The main contents of the system dynamics modeling, vibration characteristics analysis and processing deformation prediction modeling are as follows: (1) by analyzing the characteristics of the milling process system of thin-walled parts, the rigidity of the machine tool is higher than the workpiece and tool, so the machining process system is simplified to the workpiece system and the tool son. The modal analysis of the workpiece subsystem and the tool subsystem is carried out to obtain the most prominent plane of the vibration mode of the processing system, and the modal parameters such as modal mass, modal damping and modal stiffness in the plane, which provide the basis for the construction of the dynamic model of the subsequent thin-walled parts processing system. (2) a dynamic cutting force is proposed. By analyzing the mechanism of milling, the cutting process of the cutting edge is divided into three stages, and the cutting force model of the cutting edge in different time periods is established, and then the cutting force of the single tooth is integrated by analyzing the length of the single tooth cutting edge. By calculating the number of the teeth of the cutter at this time, the dynamic cutting force model of the whole tool is established by cutting all the cutter teeth. Then the milling force model based on the dynamic displacement is established through the relation of the milling force, the vibration displacement of the tool and the workpiece. Finally, the correctness of the method is verified through the experiment. (3) the system is based on the system. Modal analysis and dynamic cutting force model are used to analyze the relationship between the milling force and the vibration of the processing system. A dynamic model of the thin-walled part side wall processing system is constructed, which is used to analyze the dynamic characteristics of the machining system. Based on this model, a prediction method for the chatter stability of the thin-walled part milling is proposed. The method is adopted. The stability of the machining with different milling parameters is judged by milling stability. Finally, the correctness of the model and method is verified by experiments. (4) based on the dynamic milling force model and the prediction method of flutter stability, a finite element model for the deformation prediction of thin-walled parts is constructed, and the deformation prediction before the thin-walled parts processing is realized. In the end, the accuracy of the model is verified by the test, and the effect of the vibration on the machining deformation is analyzed by the experiment. A complete set of thin-walled parts processing is established through the study of the four aspects of the machining process of thin-walled parts. The systematic method of deformation prediction provides a guiding method and conclusion for improving the productivity of the thin-walled parts and the qualified rate of the products, and the optimization of the processing parameters.
【學(xué)位授予單位】：西南交通大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2016
【分類(lèi)號(hào)】：TG54

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