Research On Cutting Burr Active Suppression Method Of Aluminum Alloy Hub

Burr defects are common in the turning process of aluminum wheel hubs,which not only seriously reduce the aesthetics of the wheel hub surface,but also lead to incomplete coverage of the paint film in the subsequent painting process.Wheel hubs with excessive burr sizes are generally judged as defective.At present,hub manufacturers mainly solve the problem of hub cutting burr by adding deburring process,which increases the labor cost,time cost and equipment cost,and also hinders the intelligent and unmanned development process of the production line.This paper aims to realize burr-free cutting of wheel hubs and active suppression of burr size in the cutting stage,and carries out research on key issues such as the mechanism of wheel cutting burr formation,burr-free cutting technology,burr size prediction model construction,and active suppression technology of burr size,which provides a theoretical basis and technical support for wheel manufacturers to solve the problem of aluminum alloy wheel cutting burr.The main research contents include:(1)The formation mechanism model of the burr in intermittent turning of the hub is established,and the key influencing factors are clarified.Based on the analysis of the basic characteristics of the intermittent turning burr of the hub,the theoretical model of the burr formation process is established based on the elastic-plastic theory and cutting mechanics,and the stress state in each shear zone is studied;the analytical model of the burr shape and size is constructed,and the given The key factors affecting the burr shape and size lay a theoretical foundation for the study of the burr-free cutting method and the active suppression method of the burr size.(2)Build a burr-free cutting model for the hub to achieve burr-free cutting.Based on the theoretical analysis of the burr formation process,a burr-free cutting model in the exit direction was established to quantify the numerical relationship between the angle of the hub’s blade face and the burr-free cutting state,and to predict the critical blade angle for burr-free cutting.The stress cloud map of the cutting area was used to obtain the relationship between the angle of the cutting face and the shape of the burr;the cutting experiment was carried out to realize the burr-free cutting,and the feasibility of the cutting without the burr and the predicted value of the critical cutting face angle were verified.(3)Aiming at the hub that cannot meet the burr-free cutting condition,the research on the active suppression method of burr size is carried out.The Power-Law constitutive model of A356.2 aluminum alloy was constructed,the model was improved based on the mechanical test results,and the model was used to carry out cutting simulation analysis of A356.2 aluminum alloy;combined with the cutting simulation results and cutting experimental results,the factors affecting the burr were analyzed.The influence law of size,and the similar characteristics of simulation data and experimental data are studied to provide a basis for building a new method of burr size prediction model.(4)Build a deep transfer learning model to accurately predict glitch size.This paper proposes a method for constructing a burr size prediction model based on deep transfer learning that combines simulation and experimental data to solve the problem of large-scale acquisition of burr experimental samples.By constructing a one-dimensional residual network,the influence characteristics of factors in the simulation data on the burr size are learned,and the learned features are migrated based on the transfer learning method,and are integrated into the training model of the experimental data to construct the burr size prediction model,which lays a solid foundation for active suppression technology.(5)Based on the burr size prediction model and heuristic algorithm,the active suppression of wheel burr size is realized.The wheel hub cutting conditions were analyzed,and the wheel hub cutting burr optimization strategy was formulated according to the turning speed limit conditions;the improved Harris Eagle optimization algorithm was used to optimize the constructed black box model of the burr size,and the values of the influencing factors were obtained when the burr size was the smallest;Through the comparative analysis and optimization of the cutting burr size of the wheel hub before and after the cutting experiment,the effect of the active suppression method of the cutting burr size in this paper is verified.