Study On Finite Element Simulation And Parameter Optimization Of Milling 2219 Aluminum Alloy

Aerospace industry is regarded as the key development field of country,which has high requirements on the mechanical properties of parts,such as the strength and the toughness.Furthermore,the light weight is a hard demanding.Aluminum alloy is widely used in aerospace because of light weight,high strength,good corrosion resistance,etc.The application of the integral thin-walled parts effectively improves the processing efficiency and reduces the production cost.However,the manufacturability of the integral thin-walled parts of aluminum alloy is poor because the low rigidity and the large removal capacity.The processing deformation is easy to occur under the condition of the larger cutting force and higher cutting temperature,which seriously affects the processing efficiency and processing quality.Therefore,how to realize high efficiency and high precision processing of the integral thin-walled parts of aluminum alloy has been became a key problem that plagued the development of the aerospace for many years.With the progress of computer technology,finite element simulation has been became an important method for the mechanism research of metal machining.The 2219 aluminum alloy,that is an integral panel material for a new generation of carrier rocket,is taken as the investigated subject.The effect of cutting parameters on the cutting force,the cutting temperature and the surface roughness are analyzed by the finite element simulation and the experiments.Furthermore,the chatter stability domain is obtained by the dynamics simulation based on Cutpro9.3.Consequently,the parameters optimization considering the cutting force,the cutting temperature,the surface quality and the stability of the processing system is carried out.The main contents are as follows,(1)A three-dimensional(3D)finite element model for high speed milling of 2219 aluminum alloy is established based on ABAQUS,and the availability of the model built is verified by experiment.The effect of the cutting parameters on the cutting temperature is investigated by the orthogonal experiments with four factors and three levels based on the established model,and the empirical formula is fitted.(2)The orthogonal experiments with four factors(axial depth of cut ap,radial depth of cut ae,spindle speed n and feed speed f)and seven levels for milling of 2219 aluminum alloy are carried out on the vertical machining center Makino S33.The effect of the cutting parameters on the cutting force and the surface roughness is analyzed,and the empirical formulas are fitted.(3)The cutting force coefficients of 2219 aluminum alloy are identified,which provide a mechanical model for the dynamics simulation.The chatter stability domain is obtained by the hammer test and the dynamics simulation based on Cutpro9.3.Therefore,the parameters optimization is carried out based on the empirical formulas of cutting force,cutting temperature and surface roughness,as well as the dynamics simulation.Then,the optimization parameters are verified by the milling experiment.