航空框类整体结构件铣削加工变形的数值模拟与实验研究
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摘要
整体结构件数控加工变形是航空制造业面临的最突出问题之一,多年来一直困扰航空工业。研究影响整体结构件加工变形的因素及减小或抑制零件加工变形的工艺方法,对航空整体结构件数控加工变形预测及控制具有重要的意义和价值。本文在阐述航空整体结构件国内外研究现状的基础上,通过理论分析、有限元计算及实验研究相结合的方法,从三维切削机理,薄壁件变形及整体结构件数值模拟关键技术入手,对航空整体结构件的铣削加工变形进行了深入的研究。
深入研究了金属的三维切削加工机理,并采用三维斜角切削有限元模型对航空铝合金已加工表面残余应力的分布规律进行了模拟研究。另外采用更接近真实铣削过程的三维螺旋刃刀具有限元模型对航空铝合金7050-T7451铣削机理进行了数值模拟,研究了切削过程中的各种物理现象。并分析了切削力及切削温度的变化规律。
在阐述航空薄壁件加工变形的相关理论基础上,深入研究了薄壁件切削加工模拟的若干关键技术,建立了适合薄壁件加工的三维螺旋刃刀具有限元模型及带悬壁板结构的薄壁工件有限元模型。利用该模型对航空铝合金7050-T7451进行了加工变形模拟,分析了切削过程中的切削力与让刀量的关系。为航空整体结构件局部变形(侧壁、腹板、筋条、缘条)的研究和控制建立了基础。
针对航空框类结构件的结构及加工特点,建立了适合航空框类整体结构件铣削加工变形的有限元模型,并深入研究了所需的建模关键技术。关键技术主要包括框类整体结构件实际加工过程面向数值模拟过程的CAD模型简化研究、加工工艺向数值模拟的转化研究,毛坯初始残余应力场的构建,材料去除方法,切削层简化及切削载荷的获取与施加方法,数值模拟的接力计算方法。提出了采用对称铣削加工框类整体结构件的工艺方法与普通加工工艺方法进行铣削加工变形的模拟与实验对比分析。
通过小尺寸框类整体结构件进行包括对称铣削加工工艺方法在内的四种不同工艺方法的铣削加工模拟及加工实验。对四个小尺寸框类整体结构件的数值模拟及加工实验的结果进行对比分析,验证了数值模拟建模技术的正确性。同时,通过对比,证明了对称铣削加工的工艺方法能有效的减小航空框类整体结构件铣削加工变形。将对称铣削的加工工艺应用于实际尺寸的大型航空框类整体结构件的铣削加工过程模拟,进行航空框类整体结构件加工变形的预测研究。
The machining distortion of monolithic components is one of the most striking problems in aviation manufacturing industry. It has important value to investigate the effect factors of machining distortion and methods for reducing or avoiding distortion. Based on the domestic and foreign investigated status, from the three dimensional cutting principles, the distortion of thin-walled part, and the key modeling techniques of monolithic components for the simulation, a method combining theoretical analysis with finite element calculation and experiment is adopted in this dissertation to study the distortion prediction.
The cutting mechanism has been deeply investigated. Using the three dimensional oblique cutting model, the machined surface residual stress of aluminium alloy 7050T7451 has been simulated. The tool finite element model with helical edge has been used to simulate the milling process of aluminium alloy 7050T7451, and the physical value including cutting force and cutting temperature has been analyzed.
Based on the theory of cutting deformation of thin-walled parts, the key techniques of cutting simulation of thin-walled has been studied. The three dimensional finite element model of milling process for thinned-wall part has been established. The part deflection of thinned wall part has been simulated using the established model. The cutting stress, strain, and part deflection have been investigated further. Which provided the conditions for the investigation and control of local deformation.
The key modeling techniques of the machining distortion simulation for the milling process of monolithic components have been investigated, which include the simplification of geometrical model, simplification of technics, the original residual stress of raw material, simplification of cutting layer and the application and acquirement of cutting loads. The restart analysis method has been adopted to simulate the milling process of monolithic components. These provide the conditions for the machining distortion simulation of monolithic components.
Aiming at the structure and cutting characters of frame parts, the finite element model used to simulate the machining distortion has been established. The key modeling techniques of the machining distortion simulation for the milling process of monolithic components have been investigated, which include the simplification of geometrical model, simplification of technics, the original residual stress of raw material, simplification of cutting layer, the application and acquirement of cutting loads and the restart analysis method . The symmetrical milling method has been adopted in the milling simulation and experiment process of monolithic components with the common milling method.
Four technics have been used to investigate the milling distortion of small dimension frame parts in the simulation and experiment. Through the analysis and comparison of results of simulation and experiment, the finite element model has been verified. The results proved that the symmetrical milling method can decrease the milling distortion effectively. The symmetrical milling method has been used to predict and control the milling distortion of practical dimensional aviation frame part.
深入研究了金属的三维切削加工机理,并采用三维斜角切削有限元模型对航空铝合金已加工表面残余应力的分布规律进行了模拟研究。另外采用更接近真实铣削过程的三维螺旋刃刀具有限元模型对航空铝合金7050-T7451铣削机理进行了数值模拟,研究了切削过程中的各种物理现象。并分析了切削力及切削温度的变化规律。
在阐述航空薄壁件加工变形的相关理论基础上,深入研究了薄壁件切削加工模拟的若干关键技术,建立了适合薄壁件加工的三维螺旋刃刀具有限元模型及带悬壁板结构的薄壁工件有限元模型。利用该模型对航空铝合金7050-T7451进行了加工变形模拟,分析了切削过程中的切削力与让刀量的关系。为航空整体结构件局部变形(侧壁、腹板、筋条、缘条)的研究和控制建立了基础。
针对航空框类结构件的结构及加工特点,建立了适合航空框类整体结构件铣削加工变形的有限元模型,并深入研究了所需的建模关键技术。关键技术主要包括框类整体结构件实际加工过程面向数值模拟过程的CAD模型简化研究、加工工艺向数值模拟的转化研究,毛坯初始残余应力场的构建,材料去除方法,切削层简化及切削载荷的获取与施加方法,数值模拟的接力计算方法。提出了采用对称铣削加工框类整体结构件的工艺方法与普通加工工艺方法进行铣削加工变形的模拟与实验对比分析。
通过小尺寸框类整体结构件进行包括对称铣削加工工艺方法在内的四种不同工艺方法的铣削加工模拟及加工实验。对四个小尺寸框类整体结构件的数值模拟及加工实验的结果进行对比分析,验证了数值模拟建模技术的正确性。同时,通过对比,证明了对称铣削加工的工艺方法能有效的减小航空框类整体结构件铣削加工变形。将对称铣削的加工工艺应用于实际尺寸的大型航空框类整体结构件的铣削加工过程模拟,进行航空框类整体结构件加工变形的预测研究。
The machining distortion of monolithic components is one of the most striking problems in aviation manufacturing industry. It has important value to investigate the effect factors of machining distortion and methods for reducing or avoiding distortion. Based on the domestic and foreign investigated status, from the three dimensional cutting principles, the distortion of thin-walled part, and the key modeling techniques of monolithic components for the simulation, a method combining theoretical analysis with finite element calculation and experiment is adopted in this dissertation to study the distortion prediction.
The cutting mechanism has been deeply investigated. Using the three dimensional oblique cutting model, the machined surface residual stress of aluminium alloy 7050T7451 has been simulated. The tool finite element model with helical edge has been used to simulate the milling process of aluminium alloy 7050T7451, and the physical value including cutting force and cutting temperature has been analyzed.
Based on the theory of cutting deformation of thin-walled parts, the key techniques of cutting simulation of thin-walled has been studied. The three dimensional finite element model of milling process for thinned-wall part has been established. The part deflection of thinned wall part has been simulated using the established model. The cutting stress, strain, and part deflection have been investigated further. Which provided the conditions for the investigation and control of local deformation.
The key modeling techniques of the machining distortion simulation for the milling process of monolithic components have been investigated, which include the simplification of geometrical model, simplification of technics, the original residual stress of raw material, simplification of cutting layer and the application and acquirement of cutting loads. The restart analysis method has been adopted to simulate the milling process of monolithic components. These provide the conditions for the machining distortion simulation of monolithic components.
Aiming at the structure and cutting characters of frame parts, the finite element model used to simulate the machining distortion has been established. The key modeling techniques of the machining distortion simulation for the milling process of monolithic components have been investigated, which include the simplification of geometrical model, simplification of technics, the original residual stress of raw material, simplification of cutting layer, the application and acquirement of cutting loads and the restart analysis method . The symmetrical milling method has been adopted in the milling simulation and experiment process of monolithic components with the common milling method.
Four technics have been used to investigate the milling distortion of small dimension frame parts in the simulation and experiment. Through the analysis and comparison of results of simulation and experiment, the finite element model has been verified. The results proved that the symmetrical milling method can decrease the milling distortion effectively. The symmetrical milling method has been used to predict and control the milling distortion of practical dimensional aviation frame part.
引文
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