Research On Machining Deformation Prediction And Cutting Parameter Optimization Of Aluminum Alloy Thin-walled Ring Parts

Aviation aluminum alloy materials are favored in the production and manufacturing of aircraft because of their superior performance.However,affected by complex working conditions during the cutting process,the light alloy structural parts represented by ZL114 A aluminum alloy are prone to machining deformation.The machining efficiency and production cost of aerospace products are greatly affected by the rework and workpiece scrapping,and the development of aviation industry has been seriously restricted.In view of the low rigidity of aluminum alloy materials,it is difficult to achieve precise control of machining deformation by traditional cutting processing technology.Based on cutting processing theory,the finite element simulation technology was adopted to analyze cutting deformation in this paper,and research on machining deformation control of aluminum alloy ring parts was carried out.The main research contents are as follows:(1)The cutting simulation finite element model based on finite element software was established,and the cutting process of ZL114 A aluminum alloy material was also simulated.Based on the analysis of the cutting simulation results,the variation law of stress field,temperature field and cutting force in the cutting process is obtained,and the research basis for the analysis of machining deformation is provided.Aiming at the complex operation of cutting simulation process and low modeling efficiency,the parametric model of cutting simulation was established based on 3D cutting simulation research,and the visual operation interface with simple operation and graphical interaction was generated.Combined with cutting experiments,the accuracy of the simulation model was verified.The main cutting force under different cutting parameters was analyzed,and the influence degree of each cutting parameter on the main cutting force was obtained.(2)According to the actual cutting conditions,the simulation model of heat treatment of aluminum alloy ring blanks was established based on finite element software.The initial residual stress is obtained based on the heat treatment simulation of the ring blank.Based on the life-and-death element technology,the finite element model of aluminum alloy ring parts cutting machining was established,and the machining deformation prediction of aluminum alloy ring parts was realized.Measurement experiments were carried out to verify the accuracy of the machining simulation model.The machining deformation of aluminum alloy ring parts under different process parameters was analyzed,and the influence degree of each cutting parameter on the machining deformation was obtained.(3)Taking the radial deformation data of the workpiece obtained by cutting as a sample,the nonlinear mapping model between the cutting parameters and the machining deformation of the aluminum alloy ring was established.The cutting parameter optimization model with the maximum removal rate of workpiece material and the minimum machining deformation as the objective functions was established.The research result shows that machining based on optimized parameters,the capability of machine tools and cutting tools are adequately utilized,and the machining deformation of aluminum alloy ring parts is effectively reduced,and the dimensional accuracy and the efficiency are improved during the cutting process.