沉头孔螺旋铣削加工有限元仿真分析

Finite element simulation analysis in helical milling of countersunk hole

航空航天构件装配过程中需要加工大量沉头孔,难加工材料的大量使用给装配制孔技术带来了新挑战。螺旋铣孔是一种装配制孔新方法,配合特殊刀具可实现沉头孔加工,并且能够利用螺旋铣孔切削原理上的特点来提高沉头孔加工质量。首先,进行了沉头孔螺旋铣削加工的运动学分析,然后利用有限元仿真了钛合金材料沉头孔螺旋铣削过程。接下来,通过沉头孔螺旋铣削试验中的切削力和切屑形态对有限元仿真的准确性进行了验证。最后,使用建立的仿真模型分析了锪窝深度和工艺参数对钛合金沉头孔螺旋铣削过程中刀具所受切削力的影响规律。

A large number of countersunk holes need to be machined during the assembly of aerospace components.The widespread use of difficult-to-cut materials has brought new challenges to the hole-making technology.As a new hole-making technology of assembly,helical milling can be used to machine countersunk holes with special tools,and the machining quality can be improved by using the characteristics of helical milling principle.Firstly,the kinematics analysis of helical milling in machining countersunk holes was carried out.Next,finite element simulation was used to simulate the helical milling process of countersunk holes in titanium alloy materials.Then,the accuracy of the finite el⁃ement simulation was verified through the cutting force and chip morphology in helical milling test.Finally,the estab⁃lished simulation model was used to analyze the influence of dimple depth and process parameters on the cutting force acting on the cutting tool.