薄壁件残余应力变形仿真预测与切削参数优化
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摘要
针对薄壁件铣削残余应力变形难以准确预测的问题,提出了一种仿真预测方法,并在此基础上研究了薄壁件铣削切削参数优化方法。首先,提出了基于工况映射与薄壳应力贴合的残余应力变形仿真预测方法,实验结果表明该方法能够有效预测薄壁件的加工残余应力变形。在此基础上,利用支持向量回归机建立了基于切削参数的残余应力变形响应预测模型;然后,根据所建立的预测模型,采用遗传算法,以残余应力变形为约束、最大加工效率为目标对工艺参数进行优化。结果分析表明,该优化方法获得了最优的加工参数。
The prediction method of deformation induced by residual stress in milling of thin-walled parts was studied. Based on the above-mentioned,the cutting parameters were optimized. Firstly,the simulation method of deformation induced by residual stress was proposed based on the mapping of working conditions and the application of machining residual stress fields. The experimental results show that this method can effectively predict the deformation induced by using the machining residual stress of thin-walled parts. On this basis,the prediction model for deformation based on the cutting parameters was established by using the support vector regression algorithm.Then,on the basis of the present prediction model,a genetic algorithm was adopted to optimize the cutting parameters with the deformation induced by residual stress as the constraint and the maximum processing efficiency as the optimization objective. The analysis of results indicates that the optimization method presented in the paper could optimized the cutting parameters.
The prediction method of deformation induced by residual stress in milling of thin-walled parts was studied. Based on the above-mentioned,the cutting parameters were optimized. Firstly,the simulation method of deformation induced by residual stress was proposed based on the mapping of working conditions and the application of machining residual stress fields. The experimental results show that this method can effectively predict the deformation induced by using the machining residual stress of thin-walled parts. On this basis,the prediction model for deformation based on the cutting parameters was established by using the support vector regression algorithm.Then,on the basis of the present prediction model,a genetic algorithm was adopted to optimize the cutting parameters with the deformation induced by residual stress as the constraint and the maximum processing efficiency as the optimization objective. The analysis of results indicates that the optimization method presented in the paper could optimized the cutting parameters.
引文
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[15]刘中海.钛合金薄壁件精密高效切削加工机理研究[D].沈阳:沈阳航空航天大学,2011Liu Z H. Study on precise effective cutting mechanism of titanium alloy thin-walled parts[D]. Shenyang:Shenyang aerospace University,2011(in Chinese)
[2] Wang J T,Zhang D H,Wu B H,et al. Residual stresses analysis in ball end milling of nickel-based superalloy inconel 718[J]. Materials Research,2017,20(6):1681-1689
[3] Meng L H,He N,Yang Y F,et al. Measurement of surface residual stresses generated by turning thin-wall Ti6Al4V tubes using different cutting parameters[J].Rare Metal Materials and Engineering,2015,44(10):2381-2386
[4] Liu G. Study on deformation of titanium thin-walled part in milling process[J]. Journal of Materials Processing Technology,2009,209(6):2788-2793
[5] Bi Y B,Cheng Q L,Dong H Y,et al. Machining distortion prediction of aerospace monolithic components[J].Journal of Zhejiang University-SCIENCE A,2009,10(5):661-668
[6]黄志刚.航空整体结构件铣削加工变形的有限元模拟理论及方法研究[D].杭州:浙江大学,2003Huang Z G. Study on finite element simulation of distortion due to milling process for aerospace monolithic components[D]. Hangzhou:Zhejiang University,2003(in Chinese)
[7]黄志刚,柯映林,王立涛,等.基于正交切削模拟的零件铣削加工变形预测研究[J].机械工程学报,2004,40(11):117-122Huang Z G,Ke Y L,Wang L T,et al. Study on prediction of the Parts'Distortion due to milling machining based on orthogonal cutting simulation[J].Chinese Journal of Mechanical Engineering,2004,40(11):117-122(in Chinese)
[8] Rakshit A,Usui S,Marusich T D,et al. Predictive modeling for distortion in large,thin-walled machined components[J]. Advanced Materials Research,2011,223:56-65
[9]李晓燕.GH4169薄壁件铣削加工残余应力变形研究[D].西安:西北工业大学,2014Li X Y. Research on deformation caused by residual stress in milling thin-walled parts of GH4169[D].Xi'an:Northwestern Polytechnical University,2014(in Chinese)
[10]田荣鑫,刘维伟,姚倡锋,等.薄壁构件单面铣削残余应力变形有限元模拟与试验研究[J].航空精密制造技术,2015,51(6):1-4Tian R X,Liu W W,Yao C F,et al. Study on finite element simulation and experiment of distortion of residual stress during single side milling of thin-walled parts[J]. Aviation Precision Manufacturing Technology,2015,51(6):1-4(in Chinese)
[11]付秀丽,艾兴,张松,等.航空整体结构件的高速切削加工[J].工具技术,2006,40(3):80-83Fu X L,Ai X,Zhang S,et al. Research on application of high speed machining in large-scale integrated part in aircraft[J]. Tool Engineering,2006,40(3):80-83(in Chinese)
[12]何宁,杨吟飞,李亮,等.航空结构件加工变形及其控制[J].航空制造技术,2009(6):32-35He N,Yang Y F,Li L,et al. Machining deformation of aircraft structure and its control[J]. Aeronautical Manufacturing Technology, 2009(6):32-35(in Chinese)
[13]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,2012Liu H T. Research on residual stresses and deformation of thin-walled precision rotary parts induced by machining[D]. Harbin:Harbin Institute of Technology,2012(in Chinese)
[14]胡吉成,刘冠成,王瑞显.基于残余应力的弱刚度结构件加工变形分析[J].江汉大学学报:自然科学版,2015,43(3):234-241Hu J C,Liu G C,Wang R X. Analysis of machining distortion of weak-rigidity parts based on residual stress[J].Journal of Jianghan University:Natural Science Edition,2015,43(3):234-241(in Chinese)
[15]刘中海.钛合金薄壁件精密高效切削加工机理研究[D].沈阳:沈阳航空航天大学,2011Liu Z H. Study on precise effective cutting mechanism of titanium alloy thin-walled parts[D]. Shenyang:Shenyang aerospace University,2011(in Chinese)