钛合金薄壁件铣削过程有限元仿真分析
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摘要
钛合金薄壁件铣削过程中,刀具角度对铣削过程中的工件变形、铣削力、铣削振动等影响显著。为减轻刀具磨损延长刀具寿命,通过ABAQUS软件建立钛合金Ti6Al4V薄壁件铣削过程仿真模型,以铣削力和铣削温度为评价指标,采用单因素和正交法分析了刀具前角、后角及螺旋角对铣削力和铣削温度的影响规律,并对铣削力仿真结果进行试验验证。仿真结果表明:前角增大,铣削力减小,铣削温度呈波动趋势变化;后角增大,铣削力减小,铣削温度先减小后增大;螺旋角增大,最大轴向力增大,最大切向力缓慢减小,最大径向力基本不变,铣削温度先减小后增大。通过正交试验和极差分析,明确不同因素对指标影响程度的主次顺序和因素的最优水平组合。
During the milling process of titanium alloy thin-walled parts, the cutter angle has a significant influence on the workpiece deformation, milling force and milling vibration. Extend the service life of cutting tools and reduce tool wear,milling process simulation model of Ti6 Al4 V titanium alloy thin-walled pieces is established by using ABAQUS software,with the milling force and milling temperature as evaluation index, using the single factor and orthogonal method to analyze the effects of cutting tool rake angle, relief angle and helix angle on the milling force and milling temperature, and the milling force experiment is carried out to verify the simulation results. The simulation results show that with the increase of the rake angle, the milling force decreases and the milling temperature fluctuates. With the increase of the relief angle, the milling force decreases, and the milling temperature decreases first and then increases. With the increase of helix angle, the maximum axial force increases, the maximum tangential force slowly decreases, the maximum radial force has no obvious variation, and milling temperature decreases first and then increases. Through orthogonal test and range analysis, the order of primary and secondary influence degree of different factors on indexes and the optimal level combination of factors are defined.
During the milling process of titanium alloy thin-walled parts, the cutter angle has a significant influence on the workpiece deformation, milling force and milling vibration. Extend the service life of cutting tools and reduce tool wear,milling process simulation model of Ti6 Al4 V titanium alloy thin-walled pieces is established by using ABAQUS software,with the milling force and milling temperature as evaluation index, using the single factor and orthogonal method to analyze the effects of cutting tool rake angle, relief angle and helix angle on the milling force and milling temperature, and the milling force experiment is carried out to verify the simulation results. The simulation results show that with the increase of the rake angle, the milling force decreases and the milling temperature fluctuates. With the increase of the relief angle, the milling force decreases, and the milling temperature decreases first and then increases. With the increase of helix angle, the maximum axial force increases, the maximum tangential force slowly decreases, the maximum radial force has no obvious variation, and milling temperature decreases first and then increases. Through orthogonal test and range analysis, the order of primary and secondary influence degree of different factors on indexes and the optimal level combination of factors are defined.
引文
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[2]YANG F,ZHANG B,YU J.Chatter suppression via an oscillating cutter[J].International Journal of Machine Tools and Manufacture,2013,132(7):60-65.
[3]VASILYUK G D.Vibration damping in turning[J].Soviet Engineering Research,1985,5(12):73-34.
[4]ZOYA Z A,KRISHNAMURTHY R.The performance of CBN tools in the machining of titanium alloys[J].Journal of Materials Processing Technology,2011,43(11):105-509.
[5]姜振喜.TC4-DT钛合金切削性能研究与仿生刀具结构设计[D].济南:山东大学,2016.JIANG Zhenxi.TC4-DT titanium alloy cutting performance research and bionic tool structure design[D].Jinan:Shandong University,2016.
[6]张建飞.Ti6Al4V高速切削过程有限元模拟及切削参数优化[D].昆明:昆明理工大学,2017.ZHANG Jianfei.Finite element simulation of Ti6Al4V high speed cutting process and optimization of cutting parameters[D].Kunming:Kunming University of Science and Technology,2017.
[7]苗淼.钛合金TC4侧铣削刀具结构优化与刀具磨损研究[J].制造技术与机床,2016,15(1):57-71.MIAO Miao. Optimization of cutter structure and tool wear in titanium alloy TC4side milling[J].Manufacturing Technology&Machine Tool,2016,15(1):57-71.
[8]唐小同.基于钛合金三维铣削仿真的立铣刀设计参数优化[D].湖南:湖南科技大学,2017.TANG Xiaotong.Optimization of design parameters of end mill based on 3D milling simulation of titanium alloy[D].Hunan:Hunan University of Science and Technology,2017.
[9]张磊.硬质合金球头铣刀介观几何特征参数优化[D].哈尔滨:哈尔滨理工大学,2017.ZHANG Lei . Optimization of mesoscopic geometric characteristic parameters of carbide ball milling cutters[D].Harbin:Harbin University of Science and Technology,2017.
[10]朱文明,曹自洋.高速切削Ti6Al4V切屑形成及其数值模拟[J].中国机械工程,2007,19(20):2450-2454.ZHU Wenming,CAO Ziyang.Formation and numerical simulation of high-speed cutting Ti6Al4V chip[J].China Mechanical Engineering,2007,19(20):2450-2454.
[11]WU H B,ZHANG S J.3D FEMsimulation of milling process for titanium alloy Ti6Al4V[J].The International Journal of Advanced Manufacturing Technology,2014,71(5):1319-1326.