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薄壁件加工变形是影响加工精度与质量的关键因素,而切削力建模则是预测表面加工误差的基础。针对两种典型的切削力模型,系统地研究了薄壁件周铣加工过程中切削力变化及表面变形误差分布的有限元计算方法,提出了基于三维非规则网格的刀具/工件变形的耦合迭代格式以及恒定网格下材料去除效应的变刚度处理方法等关键技术,仿真过程充分考虑了切屑厚度变化及不同切削参数对预测结果的影响。以典型钛合金航空材料构件为例,数值计算结果与实验参考数据比较表明,两种切削力模型对同一切削过程的预测均具有很好的一致性。
The deformation of thin-walled parts is the key factor affecting the machining accuracy and quality, while the cutting force modeling is the basis for predicting the surface machining error. Aiming at the two typical cutting force models, the finite element method of cutting force variation and surface deformation error distribution in the process of thin wall parts milling is systematically studied. The coupling of tool / work piece deformation based on three-dimensional irregular grid Iterative format and variable stiffness processing method of material removal under constant grid. The simulation process takes full account of the influence of chip thickness variation and different cutting parameters on the prediction results. Taking a typical titanium alloy aerospace material component as an example, the numerical results are compared with the experimental data. The results show that the two cutting force models are in good agreement with the prediction of the same cutting process.