2024铝合金铣削加工表面残余应力仿真研究
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摘要
为了研究不同的铣削参数对2024铝合金铣削过程中铣削加工表面残余应力的影响,采用有限元仿真与试验验证结合的方法,利用有限元建立2D铣削仿真模型,研究铣削过程中切削表面残余应力随切削参数的变化,并在相同的切削参数下进行铣削试验测量切削表面残余应力,采用正交试验和单因素试验对铣削参数进行优化。结果表明,有限元仿真的结果与试验的结果数据相近,验证了有限元模型的准确性,通过正交试验选出最优的铣削工艺参数为切削速度500m/min、每齿进给量0.05mm/z、铣削宽度10mm、铣削深度0.5mm;在切削2024铝合金时,在不影响生产的条件下,采用较低的切削速度,较低的进给量、铣削深度和铣削宽度,得到的表面残余应力值较小。
In order to study the influence of different milling parameters on the residual stress of milling surface during 2024 aluminum alloy milling, the milling parameters were optimized to control the residual stress. Using the combination of finite element simulation and experimental verification, a 2 D milling simulation model was established by using finite element method. The residual stress of the cutting surface during milling was changed with the cutting parameters, and the milling test was carried out under the same cutting parameters to measure the residual stress of the cutting surface. The milling parameters were optimized by orthogonal test and single factor test. The results show that the results of the finite element simulation are similar to the experimental results, and the accuracy of the finite element model is verified. The optimal milling parameters are selected by the orthogonal test to be cutting speed 500 m/min and feed per tooth 0.05 mm./z, milling width 10 mm, milling depth 0.5 mm; when cutting 2024 aluminum alloy, using lower cutting speed, lower feed rate, milling depth and lower milling width without affecting production conditions, The obtained residual stress value of the surface layer is small
In order to study the influence of different milling parameters on the residual stress of milling surface during 2024 aluminum alloy milling, the milling parameters were optimized to control the residual stress. Using the combination of finite element simulation and experimental verification, a 2 D milling simulation model was established by using finite element method. The residual stress of the cutting surface during milling was changed with the cutting parameters, and the milling test was carried out under the same cutting parameters to measure the residual stress of the cutting surface. The milling parameters were optimized by orthogonal test and single factor test. The results show that the results of the finite element simulation are similar to the experimental results, and the accuracy of the finite element model is verified. The optimal milling parameters are selected by the orthogonal test to be cutting speed 500 m/min and feed per tooth 0.05 mm./z, milling width 10 mm, milling depth 0.5 mm; when cutting 2024 aluminum alloy, using lower cutting speed, lower feed rate, milling depth and lower milling width without affecting production conditions, The obtained residual stress value of the surface layer is small
引文
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[15] 陶开荣,周成,李海滨.铣削新型TC21钛合金多目标参数优化[J].航空制造技术,2014(8):86-89.
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[2] 王立涛.关于航空框类结构件铣削加工残余应力和变形机理的研究[D].杭州:浙江大学,2003.
[3] 刘海涛.精密薄壁回转体零件加工残余应力及变形的研究[D].哈尔滨:哈尔滨工业大学,2010.
[4] Liu G.Study on Deformation of Titanium Thin-walled Part in Milling Process[J].Journal of MaterialsProcessing Technology,2009,209(6):2788-2793.
[5] 徐飞飞.整体薄壁结构件残余应力预测与铣削加工变形研究[D].大连:大连理工大学,2010.
[6] MengLonghui,He Ning,Yang Yinfei,et al.Method for Measuring Residual Stresses Induced by Boring in Internal Surface of Tube and Its Validation with XRD Method[J].Transactions of Nanjing University of Aeronautics and Astronautics,2014,31(5):508-514.
[7] 刘文文,刘长毅.钛合金切削加工表面残余应力有限元仿真[J].中国制造业信息化,2012,41(3):39-42.
[8] 孙雅洲,刘海涛,卢泽生.基于热力耦合模型的切削加工残余应力的模拟及试验研究[J].机械工程学报,2011,47(1):187-193.
[9] 覃孟扬.基于预应力切削的加工表面残余应力控制研究[D].广州:华南理工大学,2012.
[10] 杨吟飞,张峥,李亮,.7085铝合金残余应力及加工变形的数值仿真与试验[J].航空学报,2014,35(2):574-581.
[11] 孔啸,李铭,卞大超.铝合金薄壁零件切削加工变形控制技术[J].机械设计与制造,2010(2):246-248.
[12] 孙会来,李丹,赵方方,等.基于ABAQUS的航空7075铝合金切削二维仿真[J].天津工业大学学报,2017,36(1):83-88.
[13] Jomaa W,Mechri O,Lévesque J,et al.Finite Element Simulation And Analysis of Serrated Chip Formation During High–speed Machining of AA7075–T651 alloy[J].Journal of Manufacturing Processes,2017,26:446-458.
[14] 黄雪红.Inconel718切削过程的有限元仿真研究[J].组合机床与自动化加工技术,2011(6):98-101,106.
[15] 陶开荣,周成,李海滨.铣削新型TC21钛合金多目标参数优化[J].航空制造技术,2014(8):86-89.
[16] Wu Q,Li D P.Analysis and X-ray measurements of cutting residual stresses in 7075 aluminum alloyin high speed machining[J].International Journal of Precision Engineering and Manufacturing,2014,15(8):1499-1506.
[17] Caruso S,Umbrello D,Outeiro J C,et al.An experimental investigation of residual stresses in hardmachining of AISI 52100 steel[J].Procedia Engineering,2011,19(6):67-72.