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针对硬质合金刀具高速内冷铣削AISI304不锈钢时,切削力大、切削温度高及加工表面质量低的问题。基于响应曲面中心复合设计方法进行高速内冷铣削实验,建立了铣削力分量二阶回归预测模型,并进行了实验验证。对比了干式与内冷铣削后的加工表面质量,分析了铣削参数对铣削力分量的影响规律,以铣削力分量最小为目标优化了铣削参数。结果表明:进给力和径向力的预测值与实验值的误差分别为4. 77%和6. 16%;内冷铣削的Ra为0. 193~0. 327μm;对铣削力分量的影响是铣削深度转速进给量,随着铣削深度和转速的增加,进给力先升高后降低,径向力逐步增加,铣削深度与转速的交互作用对进给力和径向力的影响显著;转速11 643. 63 r/min、铣削深度1 mm、进给量0. 08 mm/r为最优铣削参数组合。 相似文献
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航空航天领域大量使用的薄壁叶片等复杂曲面零件,多采用立式铣削方法加工制造。增大刀具与工件接触可以提高加工效率,但刀具的结构参数对铣削质量影响较大。建立铣削力学模型,对立式铣削加工进行分析,确定铣削加工过程中的主要影响因素是铣刀螺旋角、铣刀直径和铣刀刃数。采用AdvantEdge FEM软件,以单变量因素进行铣削有限元仿真,分析铣削力、加工形变、应力应变等影响。结果表明:铣刀螺旋角增大,铣刀半径增加,铣刀刃数增加,可有效地改善刀具应力和形变,增强刀具振动的稳定性,提高加工质量。 相似文献
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针对某型号飞机机身蒙皮精准外形需求,研制了一套机身蒙皮精准铣切系统.详细分析了机身蒙皮精准铣切系统的结构和工作原理,重点讨论了铣切系统刀具设计及其气动控制系统回路方案.机身蒙皮精准铣切系统经过安装、调试和现场应用验证,在保证安全的同时,实现了对飞机蒙皮进行切割的功能.结果表明,该系统能高效准确地完成机身蒙皮的铣切工作,保证飞机产品的制造准确度. 相似文献
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通过分析碳纤维复合材料的性能特点及对切削加工性能的影响,提出了铣削刀具材料和几何结构形式的选用原则,介绍了几种适于碳纤维复合材料铣削的加工刀具。针对碳纤维复合材料中常用的M40/4211复合材料层合板进行加工缺陷试验和切削试验,总结出影响M40/4211复合材料层合板加工质量的因素及规律,得到每种刀具加工M40/4211复合材料层合板的最佳加工参数,较高的切削速度配合恰当的进给速度可以有效提高M40/4211复合材料层合板的加工质量和加工效率。 相似文献
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In high speed milling aeronautical part, tool condition monitoring(TCM) is very important, because it is prone to get a chatter owing to the low stiffness of thin-walled structures. And the TCM is key technology for automated machining. In this paper, aiming to chatter monitoring in thin-walled structure milling, a variational mode decomposition – energy distribution(VMD-ED)method is proposed to improve the identification accuracy. And a moving average root mean square – mean value(MARMS-MV) ide... 相似文献
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In this paper, a multi-delay milling system considering helix angle and run-out effects is firstly established. An exponential cutting force model is used to model the interaction between a work-piece and a cutting tool, and a new approach is presented for accurately calibrating exponential cutting force coefficients and cutter run-out parameters. Furthermore, based on an implicit multi-step Adams formula and an improved precise time-integration algorithm, a novel stability prediction method is proposed to predict the stability of the system. The involved time delay term and periodic coefficient term are integrated as a comprehensive state term in the integral response which is approximated by the Adams formula. Then, a Floquet transition matrix with an arbitrary-order form is constructed by using a series of matrix multiplication, and the stability of the system is determined by the Floquet theory. Compared to classical semi-discretization methods and full-discretization methods, the developed method shows a good performance in convergence, efficiency, accuracy, and multi-order complexity. A series of cutting tests is further carried out to validate the practicability and effectiveness of the proposed method. The results show that the calibration process needs a time of less than 5 min, and the stability prediction method is effective. 相似文献
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Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological(MR) fluids is designed to investigate the regenerative chatter suppression during the machining.Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler–Bernoulli beam assumptions. Then,the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. 相似文献