ACTA AERONAUTICAET ASTRONAUTICA SINICA >
Deformation analysis of five⁃axis milling considering material removal effect
Received date: 2022-09-06
Revised date: 2022-09-29
Accepted date: 2022-10-31
Online published: 2023-01-01
Supported by
The Fundamental Research Funds in Beijing Jiaotong University(2022JBMC030);National Natural Science Foundation of China(52005030);China Industry University Research Cooperation Project(HFZL2020CXY014-1);China Postdoctoral Science Foundation(2021M700363);Opening Foundation of Key Laboratory of Vehicle Advanced Manufacturing, Measuring and Control Technology(M21GY1300060)
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.
Zonghao LIU , Haitong WANG , Yuwei YANG , Yonglin CAI . Deformation analysis of five⁃axis milling considering material removal effect[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023 , 44(13) : 427977 -427977 . DOI: 10.7527/S1000-6893.2022.27977
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