Study Of High-speed Processing Of The Aluminum Complex Thin-walled Structures

Complex thin-walled aluminum alloy workpieces are used more and more in aeronautics, astronautics and the area of vehicle engineering, and such other realms. Because of complex structure and low rigidity, they are easy to deform when machining and can't satisfy the machining accuracy and surface quality, so it's a very difficult problem for the aluminum alloy workpieces machining. Relied on scientific research item, based on CAD/CAE/CAM technology, using the method combined with high speed machining theory, numeric simulation, experiment validate, this paper researches on high speed machining technology of complex thin-walled aluminum alloy workpieces. The main work and relevant conclusions are as follows:Firstly, high-speed machining tool path is optimized. In other to improve the processing efficiency and improve the machining quality and tool life, analyzes the cut into strategy of the tool paths, tool moves between loops ,corner milling of tool path optimization, plane milling paths ,and that the best way to optimize the tool paths are pointed out.Secondly, analyzes processing characteristics and the control of deformation processing methods about the typical thin-walled structures such as side-wall and web. At the same time, the deformation process of the side-wall and web are modeled and simulated by the finite element software. Then, the machining deformation of the side-wall is verified through the experiments. The results are consistent with the finite element simulation results.Thirdly, the paper analyzes the workpiece's structure and machining characteristics. In order to control the deformation of the workpiece, the positioning and clamping processing program of the workpiece are identified, and a special purpose fixture is designed. At the same time, the machining process of the thin-walled workpiece are optimized, the optimum processing method of the workpiece are selected.Finally, based on the above-mentioned typical thin-walled structures' analysis, fixture design and process optimization of the workpiece, choosing the right tool and cutting parameters, the experiments of high-speed milling workpiece are done. By measuring the surface roughness of thin-walled parts, observing the detailed local appearance, the workpiece meet the requirements of the drawings.