材料切除对机匣铣削动力学与稳定性的影响
收稿日期: 2015-12-15
修回日期: 2016-01-19
网络出版日期: 2016-01-29
基金资助
国家"973"计划(2013CB035802);国家自然科学基金(51475382)
Dynamics and stability analysis in end milling of aero-engine casings considering material removal effect
Received date: 2015-12-15
Revised date: 2016-01-19
Online published: 2016-01-29
Supported by
National Basic Research Program of China (2013CB035802);National Natural Science Foundation of China (51475382)
在薄壁零件加工过程中,工件材料的连续切除会造成工艺系统动力学特性的不断变化,并对工艺系统的颤振稳定性产生显著影响。以航空发动机机匣为对象,研究了其铣削过程中工件材料切除以及切削位置变化对工件动力学特性与颤振稳定性的影响规律。首先,根据机匣的几何结构与铣削工艺特点,提出了按切削行及切削段进行材料切除过程细分的方法。其次,建立了工艺系统动力学特性演化的快速计算方法和颤振稳定性极限的频域预测方法,并在单个切削行内和不同切削行间分析了材料切除过程对工艺系统的影响。结果显示,在单个切削行内工艺系统的动力学特性会小幅度减小,稳定性极限图会向左下方小幅度偏移;在不同切削行间工艺系统的动力学特性变化幅度较大,稳定性极限图呈现出交错排列现象,难以针对整个铣削过程进行切削参数优选,因此提出了基于单行刀位轨迹的切削参数优选方法,保证了整个材料切除过程的稳定切削。最后,进行了机匣铣削与模态试验,验证了所提方法的正确性与有效性。
周续 , 张定华 , 吴宝海 , 罗明 . 材料切除对机匣铣削动力学与稳定性的影响[J]. 航空学报, 2016 , 37(4) : 1352 -1362 . DOI: 10.7527/S1000-6893.2016.0026
During the milling of thin-walled parts, the dynamic characteristics of the process system constantly vary with the material removal, which also have a significant impact on the chatter stability of the process system. The influence of material removal effect on the dynamics and stability in end milling of aero-engine casings is studied. Firstly, the material removal process is divided into several cutting lines and several cutting segments by analyzing the geometry and processing technology of the workpiece. Secondly, the calculation methods of the dynamic evolution and stability limits are developed. And the material removal effect is investigated in one single cutting line as well as in different cutting lines. The results show that the dynamic characteristics of the workpiece have a small reduction in a single cutting line but have a big change in different cutting lines, and the stability lobe diagram will have a small offset towards the left inferior side in a single cutting line but present a staggered case in different cutting lines. Then it is difficult to optimize the cutting parameters for the entire milling process. Therefore, an optimal selection approach of cutting parameters based on single line toolpath is proposed to suppress cutting chatter in the whole material removal process. Finally, several milling and hammer impact tests are carried out to validate the feasibility and effectiveness of the presented method.
[1] INSPERGER T, STÉPÁN G. Semi-discretization method for delayed systems[J]. International Journal for Numerical Methods in Engineering, 2002, 55(5):503-518.
[2] INSPERGER T. Full-discretization and semi-discretization for milling stability prediction:Some comments[J]. International Journal of Machine Tools and Manufacture, 2010, 50(7):658-662.
[3] DING Y, ZHU L M, ZHANG X J, et al. A full-discretization method for prediction of milling stability[J]. International Journal of Machine Tools and Manufacture, 2010, 50(5):502-509.
[4] BUDAK E, ALTINTAS Y. Analytical prediction of chatter stability in milling-Part I:general formulation[J]. Journal of Dynamic Systems, Measurement, and Control, 1998, 120(1):22-30.
[5] ALTINTAS Y. Analytical prediction of three dimensional chatter stability in milling[J]. JSME International Journal Series C:Mechanical Systems, Machine Elements and Manufacturing, 2001, 44(3):717-723.
[6] MERDOL S D, ALTINTAS Y. Multi frequency solution of chatter stability for low immersion milling[J]. Transactions of the ASME Journal of Manufacturing Science and Engineering, 2004, 126(3):459-466.
[7] RATCHEV S, NIKOV S, MOUALEK I. Material removal simulation of peripheral milling of thin wall low-rigidity structures using FEA[J]. Advances in Engineering Software, 2004, 35(8-9):481-491.
[8] 万敏, 张卫红, 谭刚. 薄壁件周铣过程中材料去除效应的快速仿真[J]. 航空学报, 2007, 28(5):1247-1251. WAN M, ZHANG W H, TAN G. Efficient simulation model of material removal in peripheral milling of thin-walled workpiece[J]. Acta Aeronautica et Astronautica Sinica, 2007, 28(5):1247-1251(in Chinese).
[9] SEGUY S, CAMPA F J, LÓPEZ DE LACALLE L N, et al. Toolpath dependent stability lobes for the milling of thin-walled parts[J]. International Journal of Machining and Machinability of Materials, 2008, 4(4):377-392.
[10] ZHANG X J, XIONG C H, DING Y, et al. Stability analysis in milling of thin-walled workpieces with emphasis on the structural effect[J]. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2010, 224(4):589-608.
[11] MESHREKI M, ATTIA H, KÖVECSES J. Development of a new model for the varying dynamics of flexible pocket-structures during machining[J]. Transactions of the ASME Journal of Manufacturing Science and Engineering, 2011, 133(4):041002-1-041002-14.
[12] LIU Y L, WU B H, LUO M, et al. Modeling and cutting path optimization of shallow shell considering its varying dynamics during machining[J]. Procedia CIRP, 2015, 31:521-526.
[13] ZHANG X M, ZHU L M, DING Y. Matrix perturbation method for predicting dynamic modal shapes of the workpiece in high-speed machining[J]. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2010, 224(1):177-183.
[14] ALAN S, BUDAK E, ÖZGVVEN H N. Analytical prediction of part dynamics for machining stability analysis[J]. International Journal of Automation Technology, 2010, 4(3):259-267.
[15] BUDAK E, TUNC L T, ALAN S, et al. Prediction of workpiece dynamics and its effects on chatter stability in milling[J]. CIRP Annals-Manufacturing Technology, 2012, 61(1):339-342.
[16] THÉVENOT V, ARNAUD L, DESSEIN G, et al. Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling[J]. Machining Science and Technology, 2006, 10(3):275-287.
[17] TANG A J, LIU Z Q. Three-dimensional stability lobe and maximum material removal rate in end milling of thin-walled plate[J]. The International Journal of Advanced Manufacturing Technology, 2009, 43(1-2):33-39.
[18] SONG Q H, AI X, TANG W X. Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece high-speed milling processes[J]. The International Journal of Advanced Manufacturing Technology, 2011, 55(9-12):883-889.
[19] LUO M, ZHANG D H, WU B H, et al. Modeling and analysis effects of material removal on machining dynamics in milling of thin-walled workpiece[C]//Proceedings of the 13th CIRP Conference on Modelling of Machining Operations. Sintra:CIRP, 2011:671-678.
[20] LUO M, ZHANG D H, WU B H, et al. Material removal process optimization for milling of flexible workpiece considering machining stability[J]. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2011, 225(8):1263-1272.
[21] KOIKE Y, MATSUBARA A, NISHIWAKI S, et al. Cutting path design to minimize workpiece displacement at cutting point:Milling of thin-walled parts[J]. International Journal of Automation Technology, 2012, 6(5):638-647.
[22] KOLLURU K, AXINTE D. Coupled interaction of dynamic responses of tool and workpiece in thin wall milling[J]. Journal of Materials Processing Technology, 2013, 213(9):1565-1574.
[23] CHEN D, LIN B, HAN Z L, et al. Study on the optimization of cutting parameters in turning thin-walled circular cylindrical shell based upon cutting stability[J]. The International Journal of Advanced Manufacturing Technology, 2013, 69(1-4):891-899.
[24] 王聪梅, 司克鑫, 蒋洪权, 等. 机匣制造技术[M]. 北京:科学出版社, 2002:2-28, 44-61. WANG C M, SI K X, JIANG H Q, et al. Casings manufacturing technology[M]. Beijing:Science Press, 2002:2-28, 44-61(in Chinese).
[25] 李国明. 航空发动机机匣数控加工工艺研究[D]. 大连:大连理工大学, 2012:28-52. LI G M. Study on NC machining technology of aero engine casing[D]. Dalian:Dalian University of Technology, 2012:28-52(in Chinese).
[26] OZTURK E, BUDAK E. Dynamics and stability of five-axis ball-end milling[J]. Transactions of the ASME Journal of Manufacturing Science and Engineering, 2010, 132(2):021003-1-021003-13.
/
| 〈 |
|
〉 |
CJA