钛合金薄壁件超声振动辅助铣削工艺研究

Ultrasonic vibration aided milling technology of titanium alloy thin-walled parts

在钛合金薄壁件的铣削加工过程中,存在薄壁件变形大、加工精度低等问题,为此,提出了一种基于超声振动的辅助铣削加工工艺方法。首先,分析了钛合金材料的切削变形机理,得到了影响工件变形的关键因素,为后续参数指标分析提供参考;然后,利用ABAQUS有限元仿真软件,对钛合金薄壁件的形变和受力情况进行了分析,讨论了超声振动的作用机理及其对切削力的影响;最后,在超声辅助条件下,通过单因素试验,研究了不同工艺参数对薄壁件铣削形变量的影响规律。研究结果表明:超声振动辅助加工可有效解决薄壁件铣削变形问题,大幅提高其加工精度;随着主轴转速和超声功率的增加,薄壁件的变形量呈逐渐降低的趋势;而随着进给速度的增加,薄壁变形量呈逐渐增加的趋势。该试验结果与仿真结果基本一致,与理论值的平均误差在5%以内,由此可见,该结论可为钛合金薄壁件铣削加工中参数的选择和优化提供参考。

Aiming at the problems of large deformation and low machining accuracy in milling thin-walled titanium alloy parts,an auxiliary milling process based on ultrasonic vibration was proposed.Firstly,the cutting deformation mechanism of titanium alloy was analyzed,and the key factors affecting the workpiece deformation were found out,which provided a reference for the subsequent parameter index analysis.Then,the deformation and stress of titanium alloy thin-walled parts were analyzed by using ABAQUS finite element simulation software,and the action mechanism of ultrasonic vibration and its influence on cutting force were discussed.Finally,the influence of different process parameters on the milling deformation of thin-walled parts under ultrasonic assisted conditions was studied by single factor experiment.The results show that ultrasonic vibration assisted machining can effectively solve the problem of milling deformation of thin-walled parts and greatly improve the machining accuracy.With the increase of spindle speed and ultrasonic power,the deformation of thin-walled parts decreases gradually.With the increase of feed speed,the deformation of thin-wall increases gradually.The experimental and simulation results are basically consistent,and the average error between the experimental and theoretical values is less than 5%,which provides a reference for the selection and optimization of parameters in the milling of titanium alloy thin-walled parts.