Dynamic And Static Characteristics Analysis And Structure Optimization Of Boring And Rolling Composite Tools

Deep-hole parts such as aero-engine turbine shafts,artillery barrels,EMU drive spindles,hydraulic cylinders,etc.,have been widely used in aerospace,weaponry,rail transit,construction machinery and many other industrial fields.Due to its high requirements on machining accuracy and surface quality,the traditional single hole machining process has the defects of low efficiency,large positioning error and high cost,while the advanced boring-rolling composite process has the advantages of good machining quality,high work efficiency and low cost,etc.Therefore,it has become an important method for one-step forming processing of deep holes.However,the structure of the boring-rolling composite tool is complex,and the design lacks scientific theoretical guidance,so it is difficult to meet the processing quality requirements.Therefore,how to improve the comprehensive performance of domestic composite tools to replace imported tools is a bottleneck problem that needs to be solved urgently.Therefore,this paper takes the ?160mm deep hole boring-rolling composite tool as the research object,using modern design methods,metal cutting principles,finite element analysis and other theories,with the help of Autocad2021,UG NX10.0,Hypermesh,ABAQUS,Origin and other software,as well as EK40 CNC lathes,Kistler cutting force measurement system and other equipment,systematically explore the dynamic and static characteristics analysis and structural optimization of the adjustable boring-rolling composite tool.The specific research work is as follows:(1)Do research into the factors about cutting force in deep hole boring with the method of finite element simulations and orthogonal experiment.Above all,it is ABAQUS software that was used for finite element simulation analysis of ?160mm deep hole boring processing and orthogonal experimental verification with the same parameters,obtaining the cutting force curve of the corresponding processing parameters;then by using range analysis of the experimental datas,the article will give the law of how the parameters influence the cutting force and draw a conclusion about the empirical function relation between key factors and boring force;at last,the article is about to analysize the prabable peak value,which probably appear in the process of machining,to lay the groundwork for the following analysis of dynamic and static characteristics.(2)Structural dynamics of the boring-rolling composite tool with finite element analysis.Based on the key components of the designed composite tool and the cutting force obtained from the simulation experiment,the article makes statics analysis for the designed and boring-rolling composite tool,and attemp to explore whether the deformation and displacement,stress and strain,which display in the x,y and z directions,meet the requirements or not.(3)Structural statics of the boring-rolling composite tool with finite element analysis.Different types of modal analysis and harmonious response on the basis of static analysis will be used to explore the first few natural frequencies and modal shapes of the composite tool structure in different states;the response curve of the tool structure concerning the acceleration,the displacement,the stress and the frequency in non loaded and machining condition will be output in order to obtain the resonance frequency range and resonance peak value of the structure under different working conditions.(4)The structure optimization for the boring-rolling compound tool.The article will give the geometric model of the boring process to calculate the optimum number of rough boring inserts for machining φ160mm deep holes,and also clarify the influence of various dimension parameters(such as boring inserts and guide blocks on boring),determining the appropriate dimension parameters;meanwhile,the article use UG software to optimize the structure of the boring-rolling composite tool(including boring device,rolling device and adjusting device)to adjust the accuracy of the fine boring and rolling’s size by hydraulic control,detach the key components easily and stabilize the structure rigidity.Simultaneously,the adjustment range of the fine boring and rolling will also be given in the article.In summary,the research in this paper will have good theoretical guiding significance for the dynamic and static characteristics analysis and structural optimization for the boring-rolling composite tool,and it is expected to further improve the surface machining quality of deep holes and promote the localization of boring-rolling composite tools.