Al6061-T651薄壁件高速铣削加工参数优化研究

Studyon parameters optimization of high-speed milling for Al6061-T651 aluminum alloy thin-walled parts

铝合金薄壁件刚度低,几何结构复杂,在加工过程中受到切削力及切削温度等因素的影响易发生变形。高速铣削技术具有高效和高精的优势,是铝合金薄壁件加工的最佳选择。为了选择合理的铣削参数以提高铝合金薄壁件的加工质量,基于ABAQUS 6.14建立了Al6061-T651铝合金薄壁件三维铣削有限元模型,通过正交试验极差分析研究了铣削参数对加工过程的影响,并且采用MATLAB拟合了切削力、切削温度和加工变形的经验公式。在上述基础上,开展了高速铣削参数优化研究。结果表明,所建立有限元模型切削力的预测误差在10%以内,能够对薄壁件高速铣削过程进行准确预测。铣削参数对主切削力影响程度的顺序为BCDA,对切削温度影响程度的顺序为BACD,对加工变形影响的顺序为CBDA。最后,确定优化铣削参数为:轴向切深2mm,径向切深0.2mm,主轴转速10000r/min,进给速度500mm/min。

With the low stiffness and complex geometric structure,aluminum alloy thin-walled parts are prone to deformation due to the cutting force and temperature.High-speed milling technology has the advantages of high efficiency and high precision.It is the best choice for the machining of aluminum alloy thin-walled parts.To select reasonable milling parameters and improve the machining quality,a 3Dmilling finite element model of Al6061-t651aluminum alloy thin-walled parts was established based on ABAQUS 6.14.The influence of milling parameters on the milling process was studied through range analysis of orthogonal experiment,and the empirical formulas of milling force,milling temperature and milling deformation were obtained by MATLAB.Then,the optimization of highspeed milling parameters was studied.The results showed that the prediction error of the milling force of the established finite element model was less than 10%,which could accurately predict the high-speed milling process of thin-walled parts.The effect order of milling parameters on the cutting force is BCDA,on the milling temperature is BACD,and the order is CBDA on the milling deformation.Finally,the optimized milling parameters are as follows,the axial depth of cut is 2mm,the radial depth of cut is 0.2mm,the spindle speed is 10000r/min,and the feed speed is 500mm/min.