Study On Cutting Force Model And Experiment Of Thin-Walled Component

Thin-walled structure component is widely used in aero industries. Because of its poor rigidity, the thin-walled structure is easy to deform under the cutting forces in machining process.It is difficult to ensure its machining accuracy by the traditional machining method. A method combined prediction deformation by finite element analysis with Error Compensation is presented, which is based on the cutting force model and deformation prediction.In this paper,the deep research on cutting force model and deformation prediction on thin-walled structure component is done by comparing theoretical results with experimental results.Firstly, the influence degree of each cutting parameter to cutting force is obtained by means of single-factor cutting experiment of milling TC4. Then the regressing-orthogonal experiments are carried out based on the single-factor experiment. By analyzing data collected in experiments, a regression model is established. In order to solve the regression equations rapidly and easily, we simplify the equations by matrix transformation. In this way, milling force model of TC4 can be easily obtained.Secondly, regressing-orthogonal cutting experiments with four factors and for levels of ZL114A are carried out to confirm associated coefficients of cutting force model. Then the cutting force model based on empirical formula and the model based on chip area are established by analyzing the experiment data. we select the one which can provide a convenient way to illustrate the force during cutting process by comparing their verification results. Boring force model is deduced by establishing a function of cutting force coefficients ,chip area and cutting speed. When the coefficients are obtained by analyzing the data collected from boring experiment, the boring force model is establish.Finally, a FEA (finite element analysis) model to predict deformation of thin-walled structure is built. By this model, deformation regularity can be summarized by analyzing the simulation results. In order to make sure the validity of the FEA model, related experiments are carried out to got cutting force and machining errors which will be compared with simulation ones. A conclusion is drawn that the cutting force model can describe the cutting process accurately and the method of FEA for machining errors of milling thin-walled structure is feasible by comparing the simulation results with measurement data.