CN104772648A - Milling processing method for thin-wall workpiece of airplane - Google Patents
Milling processing method for thin-wall workpiece of airplane Download PDFInfo
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- CN104772648A CN104772648A CN201510167297.5A CN201510167297A CN104772648A CN 104772648 A CN104772648 A CN 104772648A CN 201510167297 A CN201510167297 A CN 201510167297A CN 104772648 A CN104772648 A CN 104772648A
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
- B23Q15/18—Compensation of tool-deflection due to temperature or force
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2215/00—Details of workpieces
- B23C2215/04—Aircraft components
Abstract
The invention discloses a milling processing method for a thin-wall workpiece of an airplane. The method comprises the following steps that the thin-wall workpiece is installed and clamped on a clamp of a numerical control processing machine tool, a 1:10 HSK vacuum shank is selected for installing and clamping a cutter, the thin-wall workpiece is subjected to deformation analysis, a cutter feeding path preset by the cutter is compensated and corrected according to the stress deformation analysis result, the cutter feeding path during the milling process of the thin-wall workpiece is obtained, and the numerical control processing machine tool is subjected to processing setting according to the compensated and corrected cutter feeding path; finally, the numerical control processing machine tool is started for carrying out milling processing on the thin-wall workpiece according to the processing setting. The method has the advantages that on the basis of finite element analysis, the cutter is added according to the deformation degree of the original cutter feeding path during the numerical control programming in accordance with the processing deformation value, the cutter relieving quantity generated by deformation is compensated, the cutter residual materials can be cut through cutter compensation, and the wall thickness precision of the thin-wall workpiece can be ensured through once cutter feeding, so that the goal of processing a thin-wall part is achieved.
Description
Technical field
The present invention relates to the manufacture field of support class thin-wall part, be specifically related to a kind of milling method of aircraft thin-wall workpiece.
Background technology
Machinery manufacturing industry is the pillar industry that a country depends on for existence, often can show the height of a countries and regions industrialized level from a side.Along with the fierceness further of the field internationalization competitions such as Aero-Space, requirements at the higher level be it is also proposed to the performance of product, in order to alleviate product weight, improve the structural strength of product, the performance of further improving product, thin-wall construction part is used in a large number, as the trestle component etc. in aircraft structure in these fields.Its primary structure is made up of sidewall and web, and simple for structure, allowance is large, relative rigidity is lower, therefore processing technology is poor.Under the factor impacts such as cutting force, heat in metal cutting, cutting chatter, easily there is machining deformation, wayward machining accuracy and raising working (machining) efficiency.Machining deformation and working (machining) efficiency problem become the important restrictions of thin-wall construction processing.For this reason, Chinese scholars is for the special construction of milling cutter and lathe property, several dynamic and static Data Model is set up by a large amount of theoretical and experimental studies, utilize the machining deformation of finite element technique sunykatuib analysis cutter and workpiece, and thus propose some effective method for milling, the process technology of thin-wall part is had certain breakthrough.But Milling Process is a complicated metal cutting process, due to the weak separation of thin-wall part, in process, machining deformation becomes the main cause that mismachining tolerance produces, and has had a strong impact on the machining accuracy of thin-wall part.Therefore machining thin-wall construction part proposes new requirement to aspects such as cutting tool, process program, cutting data, workpiece deformations.
Summary of the invention
The object of the present invention is to provide a kind of milling method of aircraft thin-wall workpiece, it can effectively solve the problem, and improves the crudy of thin-wall workpiece, machine tooling efficiency, reduces manufacturing cost.
For achieving the above object, the present invention adopts following technical side to implement:
A milling method for aircraft thin-wall workpiece, comprises thin-wall workpiece clamping on the fixture of numerical control machine tool, selects the HSK vacuum handle of a knife tool setting tool of 1:10 to carry out clamping, and carries out deformation analysis to thin-wall workpiece, being operating as of deformation analysis:
Set up the FEM model of thin-wall workpiece, the stress deformation of thin-wall workpiece in the cutting line Milling Process thin-wall workpiece process that sunykatuib analysis is preset according to cutter, result according to stress deformation analysis compensates and revises cutting line when drawing thin-wall workpiece Milling Process to the cutting line that cutter is preset, and carries out processing sets up according to compensation and revised cutting line to numerical control machine tool;
Finally start numerical control machine tool, according to processing sets up, Milling Process is carried out to thin-wall workpiece.
Concrete scheme is: stress deformation analysis comprises the stress deformation analysis feeding direction and tool axis direction along cutter, and the object that cutting line compensates and revises comprises cutter location and the deflection angle of cutter.Cutter adopts chemical vapor deposited coatings hard alloy cutter, and coating is material is TiC.Numerical control machine tool adopt vacuum adsorption fixture carry out clamping to thin-wall workpiece.In process, cutting fluid used is the emulsion of high concentration.
In said method, on the basis of finite element analysis, according to the size of machining deformation value, allow cutter add by deformation extent in original cutting line when numerical control programming, compensate the relieving amount produced because of distortion, by cutter compensation, cutter relieving residual materials can be excised, one-pass can ensure thin-wall part wall thickness accuracy, thus reaches the object of processing thin-walled part.
Accompanying drawing explanation
Fig. 1 is trestle component sketch;
Fig. 2 is support clamping schematic diagram on numerical control machine tool;
Fig. 3-1a is the machining deformation schematic diagram of thin-wall workpiece along tool feeding direction;
Fig. 3-1b is the machining deformation schematic diagram of thin-wall workpiece along tool axis direction;
Fig. 3-2 is cutter path compensation schematic diagram;
Fig. 3-3 is that lamellar trestle component model imports marc schematic diagram;
Fig. 3-4 is that lamellar trestle component model meshes generates schematic diagram;
Fig. 3-5 is for compensating front and back cutter path change comparison diagram.
Detailed description of the invention
In order to make objects and advantages of the present invention clearly understand, below in conjunction with embodiment, the present invention is specifically described.Should be appreciated that following word only in order to describe one or more concrete embodiments of the present invention, considered critical is not carried out to the protection domain that the present invention specifically asks.
Below for aircraft rack laminal shown in Fig. 1, the present invention is specifically addressed.The machining profile of this part is by listing curve, and circular arc and straight line are formed, complex-shaped, and processing, inspection are all more difficult, and the dimensional tolerance of this part is ITl4, and surface roughness is Ra=6.3 μm, is generally not difficult to ensure.But its web thickness only has 2mm, and area is comparatively large, adds and very easily produces vibration man-hour, its wall thickness tolerance and surface roughness requirements may be caused to be difficult to reach.The blank of support is similar to part, all has monolateral allowance 5mm everywhere.Part after processing everywhere thickness size differ greatly, except fan-shaped frame, rigidity is poor everywhere for other, and especially chipping allowance relative value in web two sides is comparatively large, therefore this part all will produce moderate finite deformation in milling process and after milling.Analyze its positioning datum, only have bottom surface and Φ 70mm hole (first can make the fabrication hole of Φ 20H7) to make positioning datum, still lack a hole, need on blank, make an auxiliary process benchmark.
The machining process of thin-walled support is: 1) pincers worker: draw both sides wide line; 2) plain-milling machine: milling both sides width; 3) pincers worker: draw bottom surface milling line; 4) plain-milling machine: milling baseplane; 5) pincers worker: leveling baseplane, stroke axis of symmetry, locating hole processed; 6) machining center: rough mill web thickness machined surface profile; 7) pincers worker: leveling bottom surface; 8) machining center: finish-milling web thickness, machined surface profile and interior profile; 9) plain-milling machine: mill technique lug; 10) pincers worker: leveling bottom surface, surface finishing, sharp limit chamfering; 11) surface treatment.
One, cutter material and cutter structure are selected
1, cutter material is selected
Cutter material must wear-resisting, impact resistance good (comprise thermal shock and power is impacted), hardness is high, little with workpiece material affinity; Therefore cutter material adopts chemical vapour deposition (CVD) (CVD) cutting tool coated with hard alloy (coating material is TiC).
2, cutter structure is selected
16W and 26W series (old model is 16W1X and 16W1B) the ball end mill adapted parallelogram sphere blade of Ingersoll company is vertically-mounted.It has larger chip space, good chip removal effect, working angles friction.Outside decapacitation machined steel, cast steel, cast iron, also can milling high temperature alloy, austenitic steel and non-ferrous metal, be particularly suitable for processing various curved surface flute profile.Comprehensive above situation, the elite this ball end mill introducing production with Harbin No.1 Tool Factory.
3, knife clamping system is selected
The dynamic balance property that during cutting thin-wall construction, handle of a knife must possess, very high geometric accuracy and the requirement such as clamping repeatable accuracy, very high install rigidity.HSK vacuum handle of a knife is by the elastic deformation of handle of a knife, the not only 1:10 conical surface of handle of a knife and the 1:10 taper-face contact in machine tool chief axis hole, and making flange surface and the spindle face also close contact of handle of a knife, this double contact system is all better than the general handle of a knife of 7:24 in High-speed machining, connection rigidity and repeatable accuracy.Comprehensive above situation, the HSK vacuum handle of a knife of elite 1:10.
Two, parts fixation scheme
In NC milling operation, select bottom surface, fabrication hole on Φ 70mm hole site on prefabricated Φ 20H7 fabrication hole and technique lug is positioning datum, be i.e. " Position with One Plane and Two Holes " location.Corresponding fixture setting element is " plane and two pits ".Utilize vacuum to suck workpiece, clamping area is large, and good rigidly, not easily produces vibration during milling, is particularly useful for sheet member clamping.For anti-vacuum extractor breaks down or leaks gas, clamping force disappeared or declines, separately can add auxiliary clamping device, avoiding workpiece to loosen, as shown in Figure 2.
Three, the selection of cutting fluid and use
The factors such as the processing request according to this part, cutter and workpiece material of selecting of cutting fluid are selected, below mainly select cutting fluid according to Roughing and fine machining.
(1) the selecting of cutting fluid during roughing
During roughing, because allowance is large, cutting data used is large, and process produces a large amount of heat in metal cuttings.Select cutting fluid to distinguish to some extent, hard alloy cutter good heat resistance according to the difference of cutter material, generally without cutting fluid, can adopt low concentration emulsion or the aqueous solution if desired.The present invention here adopts the emulsion of 10% ~ 20%, the mixture of kerosene.But must pour into a mould continuously, fully, in order to avoid the carbide chip being in the condition of high temperature produces huge internal stress and occurs crackle.
(2) the selecting of cutting fluid during fine finishining
During fine finishining, because surface of thin-walled parts roughness requirements is less, use the main purpose of cutting fluid to be improve the greasy property of cutting, thus reach the requirement reducing surface roughness.So the present invention selects the emulsion of the good high concentration of greasy property, emulsion adopts a kind of semi-synthetic working fluid product containing mineral oil, concentration 10%.
Four, thin-wall part machining deformation is analyzed
The present invention selects finite element analysis software MSC.MARC to carry out sunykatuib analysis to thin-wall part machining deformation.
Thin-wall part, in milling process, because the rigidity of part is low, by there is the deformation as shown in Fig. 3-1a, 3-1b under the effect of Tool in Milling power, makes the theoretical radial cutting-in a of part
einconsistent with real cutting depth.After machining, will there is elastic deformation in part, cause occurring again new deviation between finished surface and designing requirement, affect the machining accuracy of part, cause part rejection time serious.
When milling thin-wall part, because system rigidity is poor, create cutter relieving phenomenon.At this moment, the actual radial cutting-in of cutter can reduce, thus causes the minimizing of cutting force.When climb cutting machining, blade entrance angle and cut out angle and be respectively:
Due to the inclination and distortion of cutter, workpiece, new radial cutting-in a can be produced
e' (z, φ).
a
e′(z,φ)＝a
e-δ
y(z,φ)-ω(x,z,φ)
A in formula
efor the radial cutting-in before distortion, δ
ythe radial-deformation that (z, φ) is cutter, the radial-deformation that ω (x, z, φ) is workpiece.
Like this, the rim angle of cutting zone changes:
The change of cutting zone rim angle will cause the redistribution of cutting force.
For the problem on deformation of thin-walled parts Flank machining, conventional method is after accurately machined last feed, cuts several times, although portion of residual material removal can fall by the method without feeding light, but process time increases greatly, have a strong impact on the working (machining) efficiency of part.At present, many scholars propose some control methods from improvement Workpiece structure, the optimization aspect such as frock and cutting parameter to thin-wall part problem on deformation, but these methods all can only carry out qualitative analysis, and really can not reach the effect of full remuneration.
The present invention proposes a kind of cutter path of initiatively optimizing to compensate the method for machining deformation, is namely calculated the deformation values of workpiece by FEM model, deformation values data application is formed the executable nc program with compensate function in CAM software.So-called compensate function utilizes cutter compensation exactly, on the basis of finite element analysis, according to the size of machining deformation value, allows cutter add by deformation extent in original tool track, compensate the relieving amount produced because of distortion when numerical control programming.By cutter compensation, cutter relieving residual materials can be excised, one-pass can ensure thin-wall part wall thickness accuracy, thus reaches the object of processing thin-walled part.
Fig. 3-2 is the cutter path compensation principle figure of processing thin-walled part.Add man-hour, if cutter carries out feed according to presetting cutter rail in figure, the machining deformation that so workpiece causes due to poor rigidity makes to produce between actual cut point and design point position to offset.To suppose on workpiece that certain any design point position is x
dthe actual deflection adding this point in man-hour is e, so carries out correction to this point and actual cut position is overlapped with design point position.If revised cutting point position is x
c, the perfect elasticity according to deflection replys hypothesis, cutting point position x
ccan be expressed as:
x
c＝x
d+e
Therefore, according to the deformation rule of the deformation result acquisition workpiece that finite element analysis model draws, the cutter path after recycling above formula can be optimized.
1, the finite element analysis of thin-wall part machining deformation
A, finite element modeling
The present invention is processed as example with laminal support, carries out Deformation in Milling Process analysis.First pro/e software modeling can be passed through.Imported, as shown in Fig. 3-3 by marc software again after the model established in pro/e software is preserved with vda form.
B, generating mesh
Mess generation has three kinds of basic skills: the direct definition of node and unit, or the geometry entity of first definition structure, then is converted to unit and node, and the stress and strain model to any geometric surface, the automatic generation unit of body.This example adopts the third method, finally generates FEM model as shown in Figure 3-4.
Consider that this model is in concrete stress deformation is analyzed, because cutter is different at the milling condition of diverse location, make case study complicated.Therefore Simplified analysis can be carried out for one-piece parts.The thin-wall rectangular plate side wall dimensions chosen is: long 240mm, high 40mm, thickness are 3.5mm, and the situation of part two ends without constraint only at bottom restraint carries out analytical calculation.Workpiece material is LD5 aluminium alloy, elasticity modulus of materials E=74.7Gpa, Poisson's ratio μ=0.30; Cutting tool adopts ball end mill, and cutter material is carbide alloy, tool diameter
milling mode adopts climb cutting processing, and the cutting data adopted during milling is: axial cutting-in a
p=41mm, radial cutting-in a
e=0.5mm, cutter feed engagement β
1=arctana
1=0.05mm/rev.tooth.Actual conditions according to cutting re-start three-dimensional modeling to geometrical model.Directly can set up FEM model in MARC.
C, analysis and solution
Before analysis thin plate deformation rule, between z=20 to z=40, select an observed layer totally 11 observation layer every 2mm successively; And between x=0 to the x=240 of each observed layer, select a point of observation every 20mm, totally 13.
Workpiece is subject to the effect of X, Y, Z tri-direction cutting force, all can produce corresponding distortion in three directions.Table 1 is depicted as three Direction distortions of observable each observation station along Workpiece length direction at z=30mm place.Can find out, the maximum machining deformation error of Y-direction is 0.336mm, and minimum is 0.199mm, and average machining deformation error is 0.269mm; And X is 0.03mm to maximum machining deformation error, average machining deformation error is 0.024mm; The maximum machining deformation error of Z-direction is 0.02mm, and average machining deformation error is 0.014mm, and X is to very little at the uneven deformation of Workpiece length direction each point with Z-direction, and its deformation curve and straight line are closely.Therefore can think, for Y-direction distortion, X is very little to the distortion produced with Z-direction, can ignore.Analyze from Workpiece structure, its length is 240mm, is highly 40mm, and thickness is 3.5mm, and the rigidity of obvious thickness direction is much smaller, therefore its distortion produced is just much bigger.Therefore, in deformation after unloading error analysis, will X be ignored only to consider to the machining deformation with Z-direction the machining deformation of Y-direction.
Table 1 z=30 is along the three-dimensional mismachining tolerance value in Workpiece length direction
1) along tool feeding Orientation
Its machining deformation value along Workpiece length direction of the observed layer of z=20 is as shown in table 2.Maximum distortion occurs in x=240, and namely cutter cuts out position, and its value is 0.197mm; Minimal deformation is at x=120, i.e. the centre position of rectangular slab, its value is 0.127mm.
Table 2 z=20 is along the machining deformation value in Workpiece length direction
As can be seen from Table 2:
The variation tendency of workpiece distortion inaccuracy is along its length that both sides are comparatively large, and centre is less.This is because when the position, both sides of milling workpiece, cutting point is only by the constraint of monolateral material, and rigidity is more weak; And during the centre position of milling workpiece, cutting point is subject to the common constraint of both sides material, rigid phase is to better, and machining deformation error is also relatively little.
Because workpiece is in feeding process, along with the removal of workpiece material, the rigidity of workpiece reduces gradually, and thus workpiece cuts out the distortion of distortion slightly larger than workpiece incision end of end.
2) along tool axis Orientation
Table 3 is the machining deformation value at x=0 cutting position place, and as can be seen from the table, maximum deformation quantity is 0.37mm, appears at z=34 place; Least amount of deformation is 0.03mm, appears at z=40 and workpiece free end.
Table 3 x=0 place is along the machining deformation value in tool axis direction
As can be seen from Table 3: the machining deformation amount of workpiece, in the axial direction first in increasing trend, sharply declines after reaching distortion maximum.This is the existence due to cutter helical angle, make in the incipient stage, the area of cut progressively increases, then reach a stationary value, when being cut to workpiece upper end, the area of cut again can be more and more little, cutting force can reduce thereupon, at top, the area of cut is sharply reduced to zero, and thus machining deformation is herein minimum.
The error compensation of d, thin-wall part machining deformation
Because workpiece all exists problem on deformation along in tool feeding and tool axis both direction, so cutter path compensates must consider both direction.Wherein the distortion in tool feeding direction only need revise the path of cutter location, and the distortion of cutter axial direction then needs the angle by cutter beat is certain to compensate.Consider that workpiece deformation is not straight line in the projection in tool axis direction.If compensated according to the curve shape of its projection completely, then axial cutting-in must be divided into many segments i.e. repeatedly feed, like this not only working (machining) efficiency significantly reduces, and feed below can interfere with machined surface, and compensation effect will be had a greatly reduced quality.The machining deformation curve of the present invention to axis direction carries out linear fit, and the straight slope obtained is as the deflection angle of cutter.As in Figure 3-5, it is at different cutting positions, and the deflection angle of cutter is different in cutter path contrast before and after compensating.
Assuming that survey data and do not meet:
y＝a
1x+b
1
In formula, a
1and b
1it is coefficient;
And there is residual error δ, order:
δ
i＝a
1x
i-y
i+b
1
Require that the best curve obtained should make the residual sum of squares (RSS) Δ of each data point minimum, that is:
For the extreme value asking formula (3.6), its first derivative must be zero, can obtain following equation group:
Simultaneous solution obtains initial deflection angle:
β
1＝arctana
1
To predict that the data obtained are carried out linear fit and obtained initial pivot angle β above
1=-0.458 °.The correction of cutter location position adds that the beat of cutting-tool angle constitutes revised cutter path, namely cutter is along revised cutter location orbiting motion, simultaneously cutter take cutter location as beat center beat certain angle, can obtain all cutter drift angles and cutter location is biased track.
Five, processing method is set
In Pro/NC, different numerical control machine tools and the NC sequence corresponding to processing method arrange project by different, often kind of procedure process tool route parameter form that project produces is set and applicable state also different.So, according to part pattern and technology situation, rational processing method can be selected.The step arranging processing method is as follows:
1., in " manufacture " menu of system ejection, select " processing "-" NC sequence "-" secondary process "-" processing "-" volume block "-" completing " order successively.
2. in " sequence setting " menu opened, select final election item, then select " completing " order, in " cutter setting " dialog box ejected, select " determination " button.Now system ejects editor's sequential parameter " milling of volume block " dialog box.
3. basic machined parameters is being set in editor's sequential parameter " milling of volume block " dialog box.
Six, the generation of numerical control code
Numerical control code program and machining control data (MCD) file, can generate MCD file while generation CL data file.CL data file creates from the cutter path that Pro/NC specifies, and each CL sequence creates an independent CL data file.Cutter path automatically can be merged together by the order created by Pro/NC in an operation.After having created CL data file, must post processor be sent it to, be used for exporting the G code of lathe.Pro/NC comprises a post processor, if post processor defines, just can be used to process CL file in Pro/NC to generate machine tool control data.
Seven, lathe starts and carries out Milling Process
The above is only the preferred embodiment of the present invention; should be understood that; for those skilled in the art; to know in the present invention after contents; under the premise without departing from the principles of the invention; can also make some equal conversion to it and substitute, these convert on an equal basis and substitute and also should be considered as belonging to protection scope of the present invention.
Claims (5)
1. a milling method for aircraft thin-wall workpiece, comprises thin-wall workpiece clamping on the fixture of numerical control machine tool, selects the HSK vacuum handle of a knife tool setting tool of 1:10 to carry out clamping, and carries out deformation analysis to thin-wall workpiece, being operating as of deformation analysis:
Set up the FEM model of thin-wall workpiece, the stress deformation of thin-wall workpiece in the cutting line Milling Process thin-wall workpiece process that sunykatuib analysis is preset according to cutter, result according to stress deformation analysis compensates and revises cutting line when drawing thin-wall workpiece Milling Process to the cutting line that cutter is preset, and carries out processing sets up according to compensation and revised cutting line to numerical control machine tool;
Finally start numerical control machine tool, according to processing sets up, Milling Process is carried out to thin-wall workpiece.
2. the milling method of aircraft thin-wall workpiece according to claim 1, it is characterized in that: stress deformation analysis comprises the stress deformation analysis feeding direction and tool axis direction along cutter, the object that cutting line compensates and revises comprises cutter location and the deflection angle of cutter.
3. the milling method of aircraft thin-wall workpiece according to claim 1 and 2, is characterized in that: cutter adopts chemical vapor deposited coatings hard alloy cutter, and coating is material is TiC.
4. the milling method of aircraft thin-wall workpiece according to claim 1 and 2, is characterized in that: numerical control machine tool adopts vacuum adsorption fixture carry out clamping to thin-wall workpiece.
5. the milling method of aircraft thin-wall workpiece according to claim 1 and 2, is characterized in that: in process, cutting fluid used is the emulsion of high concentration.
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