考虑材料去除效应的五轴铣削变形分析

doi:10.7527/S1000-6893.2022.27977

Abstract

Abstract:

The coupling influence of material removal effect on geometrical morphology and stiffness properties of thin-walled parts during five-axis milling process is analyzed. A five-axis cutting force model is established based on the differential element method. Aiming at the description of the geometric morphology change of material removal effect， based on the chip geometry generation principle， an analytical calculation method for the cutter-workpiece engagement region considering the curvature of the surface is proposed. To solve the engagement region， this method has no need of intersection operation， and only needs surface geometric parameters and cutter position， which improves the computational efficiency and accuracy. For the description of the property variation of stiffness properties of material removal effect， the time-varying parameters are obtained based on the perturbation method， the machining parameters affecting the engagement region are used as the calculation variables， and the machining deformation under the coupling effect of material removal is solved by iteratively calculating the cutting force， and the coupling effect law of material removal effect on the change of the geometrical morphology and stiffness of parts is obtained to improve the prediction accuracy of machining deformation. The experimental results of blade machining show that the average and maximum deviation of the deformation prediction model without considering the material removal effect on the geometrical morphology and stiffness properties coupling were 0.016 mm and 0.029 mm， respectively， while the average and maximum deviation of the prediction model considering the effect on the geometrical morphology and stiffness properties coupling were 0.011 mm and 0.021 mm， respectively. The average prediction accuracy is improved by 31.25%. The effectiveness of the deformation prediction model considering the coupling effect of influence of material removal effect on geometrical morphology and stiffness properties is verified. This model provides theoretical support for deformation prediction and error compensation in five-axis milling of thin-walled parts.

Key words: five-axis milling processing, material removal effect, cutter-workpiece engagement region, cutting force modeling, machining deformation

CLC Number:

V261

Zonghao LIU, Haitong WANG, Yuwei YANG, Yonglin CAI. Deformation analysis of five⁃axis milling considering material removal effect[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(13): 427977-427977.

Figures/Tables 15

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References 21

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摄动阶数	固有频率阶数	关键刀轨数
摄动阶数	固有频率阶数	4	8	12	15	19	22	25
一阶摄动	一阶	3.392	2.949	2.909	4.567	4.815	6.765	5.864
	二阶	2.916	2.643	3.614	4.452	5.600	5.207	5.308
	三阶	1.411	1.787	2.689	2.911	2.710	2.942	4.193
二阶摄动	一阶	2.938	1.837	1.486	3.421	4.385	6.657	5.533
	二阶	2.510	1.652	2.389	3.323	4.737	4.160	4.453
	三阶	1.149	1.336	2.405	2.919	2.909	3.189	4.282

[1]	Laixiao LU, Changguan XU, Jianhua LIU, Meizhen QIN, Yingbo LYU, Yuqin YAN. Influence of initial stress state on bilateral rolling process of thin⁃walled part [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(10): 427415-427415.
[2]	YUE Caixu, ZHANG Juntao, LIU Xianli, CHEN Zhitao, Steven Y. LIANG, Lihui WANG. Research progress on machining deformation of thin-walled parts in milling process [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525164-525164.
[3]	WAN Min, DU Yuxuan, ZHANG Weihong, YANG Yun. Cutting force modeling in helical milling process of unidirectional CFRP [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2021, 42(10): 524134-524134.

Deformation analysis of five⁃axis milling considering material removal effect

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