Study On Modeling And Simulation Of Milling Force In Milling Process Of Aluminum Alloy 7075-T6

As a common non-ferrous metal material,aluminum alloy has the characteristics of low density,high strength and corrosion resistance,so that it can be used to manufacture complex structural parts and thin-walled parts,and is widely used in many manufacturing fields such as aerospace,automobiles and ships.Because aluminum alloy milling has the disadvantages of large machining allowance and poor manufacturability,and the milling force during processing has an important influence on the generation of chatter,the deformation of the workpiece and the surface quality of the workpiece,so aluminum alloy milling is studied The milling force in the process plays a vital role in the research of aluminum alloy milling processing technology.The subject takes the milling force in the milling of aluminum alloy 7075-T6 as the research object.First,the instantaneous rigid mechanical model of the milling force of the cylindrical spiral flat end mill is established by mechanical modeling method,and the numerical simulation algorithm of the model is written.Based on the average milling force coefficient model,the finite element analysis software ABAQUS was used to establish the aluminum alloy 7075-T6 milling finite element model,and the six milling force coefficients in the instantaneous rigid mechanics model were calibrated,and the feasibility of finite element method calibration coefficients was explored.Then substitute the calibrated milling force coefficient into the numerical simulation algorithm of the instantaneous rigid mechanics model,and use MATLAB software to calculate the three-way milling force waveform diagram in one cycle,and compare it with the waveform diagram obtained from the literature experiment.The validity of the rigid mechanics model.Secondly,based on the milling finite element model,the single factor method was used to analyze the geometric parameters of the milling cutter(the number of teeth of the milling cutter,the rake angle of the milling cutter,the helix angle of the milling cutter)and the milling consumption(spindle speed,The influence of feed per tooth,axial depth of cut,radial depth of cut)on the three-way milling force and smoothness during machining.Finally,for each tooth feed,axial depth of cut,and radial depth of cut,the three factors that have a greater impact on the milling force,an orthogonal experiment is designed,and the simulation results are analyzed by range and variance analysis.Three factors affect the order and significance of the three-way milling force.The research results of the subject show that it is feasible to calibrate the milling force coefficient in the instantaneous rigid mechanics model by establishing a milling finite element model.At the same time,the established milling force instantaneous rigid mechanics model can better predict the milling force during the processing of aluminum alloy 7075-T6.The finite element simulation technology can be used to determine the geometric parameters of the milling cutter and the amount of milling during the milling of aluminum alloy 7075-T6.The choice to provide reference is of important reference and guiding significance for giving full play to the physical properties of the material and constructing a processing technology compatible with the material.