航空结构件铣削加工变形仿真技术研究与应用

Research and Application of Machining Deformation Simulation on Aero-Component

针对航空结构件在铣削加工过程中易产生变形等问题,探讨了结构件铣削加工有限元仿真方法,逐步解决了本构模型建立、毛坯初始应力场构建、切削载荷施加、网格细化与状态更新等系列问题。根据建立的有限元模型对试验件进行了加工变形仿真和铣削加工试验,结果表明仿真结果与试验结果相吻合,可满足工程应用需要。同时,提出了先加工两端后加工中间的加工变形控制策略,并采用该策略对大尺寸铝合金单面框进行了工艺设计。通过加工变形仿真验证了工艺方案的可行性。实际加工结果表明变形量和变形趋势与加工结果基本吻合,实现了大型航空结构件的一次加工合格。

In order to establish a comprehensive model for simulating the machining deformation,it was studied a series of key techniques including constitutive model,residual stress,material removal,finite element control etc.Subse-quently,a milling test was conducted to verify the model.The result shows that the simulation accords with the experiment,which means the model meets the requirement of engineering.Thus the model was used for optimizing the processing of the large integral aero-component.