航空铝合金薄壁件加工变形有限元仿真与分析.docVIP

笺鬈帮铲,。u浙rna,。f江Zhejia大ng un学ive商t学y(En器:王差黑。。,溉iz是器s 航空铝合金薄壁件加工变形有限元仿真与分析 毕运波,柯映林,董辉跃 (浙江大学机械与能源工程学院,浙江杭州310027 摘要:综合考虑薄壁件粗精加工工序,建立了薄壁件铣削加工全过程三维有限元模型,系统地研究了残余应力施加、切削力建模及动态加载、材料去除等加工过程建模所涉及的关键技术.通过白行构建的加工仿真平台,对处在不同毛坯初始残余应力分布情况下的薄壁件分别进行了加工过程模拟.仿真结果表明,加工过程中残余应力对切削力引起的薄壁件加丁变形具有重要影响,较大的初始残余应力导致薄壁件侧壁首末自由端附近产生加工变形波动,容易引起或加剧切削振动,严重影响其加工精度及表面质量. 关键词:薄壁件;加工变形;残余应力;加工过程仿真 中图分类号:TP391;THl23.2文献标识码:A文章编号:1008—973X(200803—0397一06 Finite element simulation and analysis of deformation in machining of aeronautical aluminum alloy thin。。walled workpiece BI Yun-bo,KE Ying-lin,DONG Hui—yue (College of Mechanical and Energy Engineering,孙ejiang University,Hangzhou310027,China Abstract:In comprehensively consideration of the rough—and finish-machining processes,a three-dimen—sional finite element model was developed for the whole milling process of thin-walled workpiece.Some key techniques including residual stress imposing,cutting force modeling and dynamic loading,material re—moval and SO on were discussed.By a prototype version of the developed simulation environment,different milling processes of thin-walled workpiece were simulated under the conditions of different initial residual stress distribution in blank.Simulation shows that the residual stress has great effect on the machining de—formation caused bycutting force.Greater magnitude of initial residual stress results in the deformation vi—bration near the two free ends of the side wall,and it can lead to or increase the machining vibration which will influence the machining precision and surface quality seriously. Key words:thin-walled workpiece;machining deformation;residual stress;machining process simulation 在现代航空航天工业中,大量采用薄壁型整体结构件作为主要受力构件,如整体框、梁、壁板等.这些航空薄壁件大多结构复杂、相对刚度较低、尺寸精度要求较高,在数控加工过程中,常因残余应力、切削力、切削热、装夹力等因素的影响产生加工变形,甚至报废.目前,国内外对薄壁件加工变形的研究[1-5]很多,主要是借助有限元模拟技术对切削过程中薄壁件侧壁、腹板、整体变形进行加工仿真,预测其加工变形规律.大部分研究者认为切削力引起的弹性变形是薄壁件侧壁和腹板加工变形的主要因素,而薄壁件整体加工变形主要是受残余应力的影响.更进一步,黄志刚等人[6]综合考虑残余应力、铣削力和铣削热等因素,研究了铣削加工顺序对框类薄壁结构件整体加工变形的影响.本文通过建立薄壁件加工全过程