Engine Block Drilling Simulation And Cutting Parameters Optimization Based On DEFORM-3D

Machine manufacturing industry is the basis of nation economy and the centralized reflection of nation strength. The machining processing craft level directly and deeply affects manufacturing industry. The fast development of economy demands machine manufacturing industry of high quality and efficiency. And traditional processing craft design methods can hardly meet the need.With the development of computer technology, modern design methods such as CAM, CAE and CAPP have been much developed and been more and more widely used in all fields of scientific research and production. Cutting parameters optimization based on machining simulation can timely supply valuable data for designers, helping to optimize processing craft so as to improve production quality and increase efficiency, which is of great significance to the manufacturing capacity of a company as well as the whole nation.Using the software of DEFORM-3D, the drilling process of an engine block was simulated. Some important problem setting that will greatly affect calculating efficiency and result data quality including model simplification and mesh rebuilding parameters setting was researched based on simulation work experience and knowledge.The linear function equation of cutting load to cutting parameters was obtained from the exponential equation based on experiments. Referring to the cutting parameters from manuals,11simulation projects were carried out. The cutting speed is171m/min and the feed speed varies from0.2mm/r to0.6mm/r. Drilling load data was extracted from the simulation result. Comparing the noise data of machining simulation to the real condition, a method based on statistics analysis was put forward to kick out bad quality data. And at the same time, a function curve smoothening method was developed based on wavelet analysis. The drilling simulation data was processed using the above mentioned methods, improving the data quality.The regression analysis of the drilling simulation result data was carried out using the software of Excel, which proved the good quality of the result data and supplied the function equation of drilling load to cutting parameters. The constraints were defined with all parts of a processing craft system considered. Particle swarm optimization was chosen. The program with clear structure and high efficiency was finished in the software of MATLAB. And3-D graph of the object function was generated by the program, proving the reliability of optimization result. Compared to the original cutting parameters, the optimization result theoretically brings a decrease of44.32%to the drilling process time.