航空结构件铣削加工变形仿真技术研究与应用
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摘要
针对航空结构件在铣削加工过程中易产生变形等问题,探讨了结构件铣削加工有限元仿真方法,逐步解决了本构模型建立、毛坯初始应力场构建、切削载荷施加、网格细化与状态更新等系列问题。根据建立的有限元模型对试验件进行了加工变形仿真和铣削加工试验,结果表明仿真结果与试验结果相吻合,可满足工程应用需要。同时,提出了先加工两端后加工中间的加工变形控制策略,并采用该策略对大尺寸铝合金单面框进行了工艺设计。通过加工变形仿真验证了工艺方案的可行性。实际加工结果表明变形量和变形趋势与加工结果基本吻合,实现了大型航空结构件的一次加工合格。
In order to establish a comprehensive model for simulating the machining deformation, it was studied a series of key techniques including constitutive model, residual stress, material removal, finite element control etc. Subsequently, a milling test was conducted to verify the model. The result shows that the simulation accords with the experiment,which means the model meets the requirement of engineering. Thus the model was used for optimizing the processing of the large integral aero-component.
In order to establish a comprehensive model for simulating the machining deformation, it was studied a series of key techniques including constitutive model, residual stress, material removal, finite element control etc. Subsequently, a milling test was conducted to verify the model. The result shows that the simulation accords with the experiment,which means the model meets the requirement of engineering. Thus the model was used for optimizing the processing of the large integral aero-component.
引文
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[3]吴泽刚,刘宝良,孙剑飞,等.航空发动机TC4机匣加工变形控制研究[J].航空制造技术,2017,60(21):62-67,69.WU Zegang,LIU Baoliang,SUN Jianfei,et al.Study on controlling machining distortion of aeroengine TC4 casing[J].Aeronautical Manufacturing Technology,2017,60(21):62-67,69.
[4]万晓航,董兆伟,王兵.零件结构对加工变形影响的仿真与实验研究[J].机械设计与制造,2016(7):107-109.WAN Xiaohang,DONG Zhaowei,WANG Bing.The integrated frame structure type influencing on machining deformation simulation and experiment research[J].Machinery Design&Manufacture,2016(7):107-109.
[5]龚潺,徐锋,徐俊华,等.航空薄壁结构件铣削加工变形数值模拟分析[J].机械制造与研究,2013(4):16-20.GONG Chan,XU Feng,XU Junhua,et al.Numerical simulation analysis of milling distortion for aero-thin-walled components[J].Machine Building&Automation,2013(4):16-20.
[6]徐文臣,单德彬,李春峰,等.TA15钛合金的动态热压缩行为及其机理研究[J].航空材料学报,2005,25(4):10-19.XU Wenchen,SHAN Debin,LI Chunfeng,et al.Study on the dynamic hot compression behavior and deformation mechanism of TA15titanium alloy[J].Journal of Aeronautical Materials,2005,25(4):10-19.
[7]何宜柱,陈大宏,雷廷权,等.热变形动态软化本构模型[J].钢铁,1999,34(9):29-33.HE Yizhu,CHEN Dahong,LEI Tingquan,et al.Constitutive models of dynamic restoration of during hot deformation[J].Iron and Steel,1999,34(9):29-33.
[8]蔡春波.1050铝合金变形和再结晶过程中的织构演变研究[D].哈尔滨:哈尔滨理工大学,2009.CAI Chunbo.Study on the evolution of texture of 1050 aluminium alloy during process of deformation and recrystallization[D].Harbin:Harbin University of Science and Technology,2009.
[9]成群林,柯映林,董辉跃,等.航空整体结构件铣削加工变形预测研究[J].浙江大学学报(工学版),2007,41(5):799-803.CHENG Qunlin,KE Yinglin,DONG Huiyue,et al.Distortion prediction for milling process of aerospace monolithic components[J].Journal of Zhejiang University(Engineering Science),2007,41(5):799-803.
[10]吴红兵,贾志欣,张学昌,等.航空框类结构件铣削变形的数值建模研究[J].中国机械工程,2009,20(11):1322-1325.WU Hongbing,JIA Zhixin,ZHANG Xuechang,et al.Study on modeling of numerical simulation milling deformation for aerospace frame monolithic components[J].China Mechanical Engineering,2009,20(11):1322-1325.
[11]张洪伟,张以都,赵晓慈,等.航空结构件加工变形仿真关键技术[J].北京航空航天大学学报,2008,34(2):239-243.ZHANG Hongwei,ZHANG Yidu,ZHAO Xiaoci,et al.Key techniques in simulation of machining distortion for aeronautical monolithic component[J].Journal of Beijing University of Aeronautics and Astronautics,2008,34(2):239-243.