CN107657129A - Thin-wall part residual stress deformation based on clamping power monitoring perceives Forecasting Methodology - Google Patents
Thin-wall part residual stress deformation based on clamping power monitoring perceives Forecasting Methodology Download PDFInfo
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- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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Abstract
The invention discloses a kind of thin-wall part residual stress deformation based on clamping power monitoring to perceive Forecasting Methodology, for solving the technical problem of existing thin-wall part residual stress Deformation Prediction method poor practicability.Technical scheme is to estimate the residual stress deformation tendency of thin-wall part by finite element simulation method first, and in large deformation region, addition clamping power perceives point；Then design perceives fixture, passes through the change of pressure sensor clamping power in point monitoring process is perceived；Finally by the FEM model for establishing mounting and clamping system static determinacy base, the counter-force of point application clamping power changing value is being perceived, the residual stress deformation of part is being obtained, realizes the prediction of thin-wall part residual stress deformation.The present invention need not obtain accurate forming residual stress value, solving existing thin-wall part residual stress Deformation Prediction method application forming residual stress inaccuracy causes the big technical problem of Deformation Prediction error, solves the technical problem that the deformation of thin-wall part residual stress is difficult to Accurate Prediction simultaneously, practicality is good.
Description
Technical field
The present invention relates to a kind of thin-wall part residual stress Deformation Prediction method, it is more particularly to a kind of based on clamping power monitoring
The deformation of thin-wall part residual stress perceives Forecasting Methodology.
Background technology
Finite element simulation is the research method of residual stress Deformation Prediction main at present.At present to residual stress deformation
Emulating the method generally used is：Deformed for initial residual stress, the blank initial residual stress that measurement obtains is applied to
On blank FEM model, the removal of the method artificial material of range site life and death, final part structure and stress distribution are obtained
State, and then obtain initial residual stress deformation；Deformed for forming residual stress, use obtains X-ray diffraction measurement more
A certain fixed operating mode under processing surface residual stress be distributed to part top layer apply method, stress equilibrium obtain processing it is residual
Residue stress deforms.
Document " Finite Element Modeling of Part Distortion, ICIRA 2008, Part II,
LNAI 5315, pp.329-338,2008. " disclose a kind of method of thin-wall part residual stress Deformation Prediction.This method uses
Finite element simulation technology, the forming residual stress for measuring obtained blank material initial residual stress and piece surface is applied to
On the FEM model of part, by emulating tool cutting process, realize that material removes, the remnants that final prediction obtains part should
Force deformation.
The application of the above method has very big limitation, can only be directed to simple operating mode, the ideal of simple design of part part
Machining state deploys simulation study, larger with actual processing gap.In actual processing, due to tool wear, material skewness
Etc. the influence of factor, the inconsistent inaccuracy that result in stress application of forming residual stress distribution under same fixed operating mode；In addition,
The complicated moulding surface structure of most thin-walled parts, the processing operating mode of time-varying, also result in residual stress and are difficult to accurately obtain, now without
Method is deformed using the method Accurate Prediction residual stress of finite element simulation.
The content of the invention
In order to overcome the shortcomings of existing thin-wall part residual stress Deformation Prediction method poor practicability, the present invention provides a kind of base
Forecasting Methodology is perceived in the thin-wall part residual stress deformation of clamping power monitoring.This method is estimated by finite element simulation method first
The residual stress deformation tendency of thin-wall part, in large deformation region, addition clamping power perceives point；Then design perceives fixture, passes through pressure
The change of force snesor clamping power in point monitoring process is perceived；Finally by the finite element for establishing mounting and clamping system static determinacy base
Model, the counter-force of point application clamping power changing value is being perceived, obtaining the residual stress deformation of part, realizing thin-wall part remnants should
The prediction of force deformation.The present invention need not obtain accurate forming residual stress value, solve existing thin-wall part residual stress deformation
Forecasting Methodology, which applies forming residual stress inaccuracy, causes the big technical problem of Deformation Prediction error.Due to by sensor monitoring technology
It is applied in thin-wall part processing, solves the problems, such as that the deformation of thin-wall part residual stress is difficult to Accurate Prediction, practicality is good.
The technical solution adopted for the present invention to solve the technical problems：A kind of thin-wall part based on clamping power monitoring is remaining should
Force deformation perceives Forecasting Methodology, is characterized in comprising the following steps：
Step 1: determine clamping power perceived position.In finite element analysis software, the threedimensional model of part is established, to building
Vertical FEM model assigns material properties, boundary condition, to the model partition grid to obtain multiple units, on top layer
Unit applies an approximate forming residual stress distribution according to away from finished surface depth, submits finite element analysis, estimates part
Deformation state.Apply clamping power perception point deforming larger position.
Step 2: design fixture scheme.The perception fixture of design specialized, perceived for ease of clamping power, superfluous constraint is set
A constrained type is counted into, pressure sensor is installed on a constraint clamping.
Step 3: processing perceives.The fixture scheme clamping parts designed by step 2, part is completed according to given operating mode
Processing.The numerical value of clamping power is recorded in the detecting period point of setting.
Step 4: residual stress deformation solves.
(a) mathematical modeling that residual stress deformation perceives prediction is established.
The mathematical modeling for perceiving prediction is expressed as follows：
S=f (Δ E) (1)
In formula, Δ E is vectorial to perceive：Difference perceives moment (1~m) different perceived position (1~n) clamping power changing values.
It is E to define initial clamping power0=[e01 e02 … e0n], each element represents the 1~n of perceived position of initial time 0 clamping power, its
In the numerical value of each element need to determine by sensor senses.The process of part is sharp equivalent to being provided to sensory perceptual system
Encourage, change clamping power, the clamping power for defining the moment 1 is E1=[e11 e12 … e1n], then clamping power change vector Δ E1=
E1-E0, with the progress of working angles, taking for new perception moment is fixed, and the clamping power perceived is respectively E2 E3 … Em, it is right
The clamping power change vector that should be extended is respectively Δ E2 ΔE3 … ΔEm, the perception vector of whole working angles is Δ E=
[ΔE1 ΔE2 … ΔEm]T.Embodiment perceives the change for the perception point position clamping power that vector determines for step (a) before and after processing
Change value.
S predicts object vector to perceive：Difference perceives moment (1~m) different perceived position (1~n) part residual stress
Deformation vector.Object vector S=[S1 S2 … Sm]T, each element represent it is different perception moment parts residual stress deflections,
I.e. in the residual stress deflection of different perception moment release clamping parts diverse locations.Wherein Si=[Si1 Si2 … Sin] generation
I-th of perception moment of table, the residual stress deformation values of part diverse location, it should be noted that differ each element value position
It is fixed corresponding with perceived position.It is residual stress deformation vector of the part along length center line that embodiment, which perceives prediction object vector,.
f:Δ E → S is to perceive the mapping relations that vector arrives object vector.The mapping relations solve target by perceiving vector
Vector, so as to realize that the perception to residual stress deformation is predicted.The mapping relations pass through theory deduction, finite element simulation or intelligence
Can the acquisition of algorithm means.Embodiment obtains the mapping relations using the means of finite element simulation.
(b) solution of forecast model is perceived.
The solution perceived for the deformation of n times indeterminate mounting and clamping system residual stress, has following in different superfluous constraint points
Coordinate deformation equation group：
In formula:
eiRepresent the changing value of restraining force in each superfluous constraint；
δij(i=1,2,3 ..., n；J=1,2,3 ..., n；) statically determinate structure is represented in ejDuring=1 independent role, along eiDirection
Displacement；
ΔiMStatic determinacy based structures are represented under residual stress independent role, along eiThe displacement in direction；
Thus, the solution formula of the indeterminate clamping structure sensor model of n times has just been obtained：
ΔM=-δ e (3)
In formula:
Residual stress deformation after parts fixation unloading is equal to the counter-force independent role for perceiving point clamping power changing value zero
Caused deformation on part, that is, obtain the deformation state of part.Deformation state now is the remnants after parts fixation unloading should
Force deformation value.
The beneficial effects of the invention are as follows：The residual stress that this method estimates thin-wall part by finite element simulation method first becomes
Shape trend, in large deformation region, addition clamping power perceives point；Then design perceives fixture, and point prison is being perceived by pressure sensor
Survey the change of clamping power in process；Finally by the FEM model for establishing mounting and clamping system static determinacy base, apply perceiving point
The counter-force of clamping power changing value, the residual stress deformation of part is obtained, realizes the prediction of thin-wall part residual stress deformation.This hair
It is bright to obtain accurate forming residual stress value, it is residual to solve existing thin-wall part residual stress Deformation Prediction method application processing
Residue stress inaccuracy causes the big technical problem of Deformation Prediction error.Due to sensor monitoring technology is applied into thin-wall part processing
In, solve the problems, such as that the deformation of thin-wall part residual stress is difficult to Accurate Prediction, practicality is good.
The present invention is elaborated with reference to the accompanying drawings and detailed description.
Brief description of the drawings
Fig. 1 is predicted in thin-wall part residual stress deformation perception Forecasting Methodology embodiment of the present invention based on clamping power monitoring
As a result with the comparison diagram of measured result.
Embodiment
Reference picture 1.The present embodiment should for the remnants perceived after the parts fixation unloading of prediction sheet member single-sided process process
Force deformation.Thin plate blank material is GH4169, size 160*20*2mm, takes intermediate region processing 80*20mm surface, processing
Depth is 0.5mm, and both ends respectively stay 40*20mm region to be used for clamping.Sheet member passes through destressing heat treatment before processing, remaining
Stress deformation is mainly introduced by top layer forming residual stress to be caused.
Thin-wall part residual stress deformation of the present invention based on clamping power monitoring perceives Forecasting Methodology and comprised the following steps that：
Implementation steps 1：Determine clamping power perceived position.
To determine perceived position, the forming residual stress of sheet member mounting and clamping system static determinacy base is established in Abaqus softwares
Deformation Prediction analysis finite element model, process are as described below：
The foundation of model and basis instrument：The threedimensional model of thin plate is established, thin plate machined surface top layer is divided into 7 layers, often
Layer 15um, this is the zone of action of forming residual stress.Setting light sheet material is GH4169, thin plate one end fixed constraint, using 8
Node hexahedron Reduced Integral solid element C3D8R grid divisions, discrete part is 192000 units；
Table 1 processes surface residual stress distribution
The application of residual stress：Residual stress distribution shown in table 1 is applied on each layer by depth.This residual stress is to adopt
Obtained with after parameter Milling Process GH4169 material blocks used during experiment by X-ray diffraction measurement.σXXEnter for finished surface edge
To the residual stress of velocity attitude, σYYFor the residual stress in finished surface vertical feed direction.Processed according to variable working condition, due to
Fixed cutting tool cuts residual stress in certain condition range has similar distribution character, can apply the operating mode on processing top layer
In the range of a certain parameter under residual stress distribution be used for maximum distortion position assessment；
The calculating of residual stress deformation and postpositive disposal：According to result of finite element, after obtaining part Milling Process
Aberration nephogram, the residual stress deformation state of part under static determinacy clamping is obtained by FEM model, it is known that sheet member one side
Processing is overall to be presented flexural deformation, and maximum distortion position is located at part length boundary.Consider actual clamping limitation, will perceive a little
It is arranged on away from border 10mm width midpoints.
Implementation steps 2：Design fixture scheme.
This paper fixtures use flat board one end platen clamp, mode of the end point to a clamping.Face is each up and down at point-to-point end
One clamping force sensor is installed, sensor is that circular arc millet cake contacts with feature contacts face.Clamping force sensor parameter used is such as
Under：Range 0-1000N, sensitivity 1.0mv/V.It is corresponding in upper and lower clamp member in order to ensure being accurately positioned for point-to-point position
Respectively there are three threaded locating holes position, and the accuracy of sensor mounting location is ensured together with sensor upper screwed hole.On in addition,
Lower clamp part is assembled by the way of nested, it is ensured that point-to-point clamping.
Implementation steps 3：Processing perceives.
Experiment is carried out on YH850 numerical control machining centers, is processed using two tooth flat-bottom milling cutters.Cutting-in 0.5mm, wide 2mm is cut,
Cutting speed 80m/min.Clamping force numerical value is obtained using high-precision display instrument.Fixture top is obtained before processing by display instrument to pass
Sensor perception value is 31.6N, lower sensor 32.8N.After processing, upper sensor perception value is 30.8N, and lower sensor is
34.6N。
Implementation steps 4：The solution of residual stress deformation.
The deformation of thin-wall part residual stress solves to be carried out by following steps：
(a) mathematical modeling that residual stress deformation perceives prediction is established.
The mathematical modeling for perceiving prediction is expressed as following form：
S=f (Δ E) (1)
In formula, Δ E is vectorial to perceive：Difference perceives moment (1~m) different perceived position (1~n) clamping power changing values.
It is E to define initial clamping power0=[e01 e02 … e0n], each element represents the 1~n of perceived position of initial time 0 clamping power, its
In the numerical value of each element need to determine by sensor senses.The process of part is sharp equivalent to being provided to sensory perceptual system
Encourage, change clamping power, the clamping power for defining the moment 1 is E1=[e11 e12 … e1n], then clamping power change vector Δ E1=
E1-E0, with the progress of working angles, taking for new perception moment is fixed, and the clamping power perceived is respectively E2 E3 … Em, it is right
The clamping power change vector that should be extended is respectively Δ E2 ΔE3 … ΔEm, the perception vector of whole working angles is Δ E=
[ΔE1 ΔE2 … ΔEm]T.Embodiment perceives the change for the perception point position clamping power that vector determines for step 1 before and after processing
Value.
S predicts object vector to perceive：Difference perceives moment (1~m) different perceived position (1~n) part residual stress
Deformation vector.Object vector S=[S1 S2 … Sm]T, each element represent it is different perception moment parts residual stress deflections,
I.e. in the residual stress deflection of different perception moment release clamping parts diverse locations.Wherein Si=[Si1 Si2 … Sin] generation
I-th of perception moment of table, the residual stress deformation values of part diverse location, it should be noted that differ each element value position
It is fixed corresponding with perceived position.It is residual stress deformation vector of the part along length center line that embodiment, which perceives prediction object vector,.
f:Δ E → S is to perceive the mapping relations that vector arrives object vector.The mapping relations solve target by perceiving vector
Vector, so as to realize that the perception to residual stress deformation is predicted.The mapping relations pass through theory deduction, finite element simulation or intelligence
Can the acquisition of algorithm means.Embodiment obtains the mapping relations using the means of finite element simulation.
(b) solution of forecast model is perceived.
The solution perceived for the deformation of n times indeterminate mounting and clamping system residual stress, has following in different superfluous constraint points
Coordinate deformation equation group：
In formula:
eiRepresent the changing value of restraining force in each superfluous constraint；
δij(i=1,2,3 ..., n；J=1,2,3 ..., n；) statically determinate structure is represented in ejDuring=1 independent role, along eiDirection
Displacement；
ΔiMStatic determinacy based structures are represented under residual stress independent role, along eiThe displacement in direction；
Thus, the solution formula of the indeterminate clamping structure sensor model of n times has just been obtained：
ΔM=-δ e (3)
In formula:
The counter-force independent role that residual stress deformation i.e. after parts fixation unloading is equal to perception point clamping power changing value exists
Caused deformation on part.Embodiment is 2 indeterminate mounting and clamping systems, suitable for the method for solving.
From solution formula (3), sheet member residual stress deforms the load for being equivalent to be downwardly applied to 2.6N on part
Caused deformation values.Limit element artificial module is established in Abaqus, setting light sheet material is GH4169, and thin plate one end is fixed about
Beam, using 8 node hexahedron Reduced Integral solid element C3D8R grid divisions, discrete part is 192000 units；Perceiving
Point applies the Aberration nephogram that downward 2.6N load obtains part, extracts the deformation numerical value along length center line.Unloaded after machining
Carry and perceive end clamping, deformation of the part along length center line direction is measured using strain gauge.
It is 1.07mm to contrast perception prediction result to can be seen that actual measurement maximum distortion with measured result from Fig. 1, is perceived maximum
0.93mm is deformed into, it is 13% that maximum, which perceives prediction error, and existing residual stress limited deformation member Forecasting Methodology error exists
30% or so, perceive prediction and achieve more accurate result.
Claims (1)
1. a kind of thin-wall part residual stress deformation based on clamping power monitoring perceives Forecasting Methodology, it is characterised in that including following step
Suddenly：
Step 1: determine clamping power perceived position；In finite element analysis software, the threedimensional model of part is established, to foundation
FEM model assigns material properties, boundary condition, to the model partition grid to obtain multiple units, in top layer unit
Apply an approximate forming residual stress distribution according to away from finished surface depth, submit finite element analysis, estimate the change of part
Shape state；Apply clamping power perception point deforming larger position；
Step 2: design fixture scheme；The perception fixture of design specialized, perceived for ease of clamping power, superfluous constraint is designed to
Point constrained type, pressure sensor is installed on a constraint clamping；
Step 3: processing perceives；The fixture scheme clamping parts designed by step 2, adding for part is completed according to given operating mode
Work；The numerical value of clamping power is recorded in the detecting period point of setting；
Step 4: residual stress deformation solves；
(a) mathematical modeling that residual stress deformation perceives prediction is established；
The mathematical modeling for perceiving prediction is expressed as follows：
S=f (Δ E) (1)
In formula, Δ E is vectorial to perceive：Difference perceives moment (1~m) different perceived position (1~n) clamping power changing values；Definition
Initial clamping power is E0=[e01 e02 … e0n], each element represents the 1~n of perceived position of initial time 0 clamping power, wherein respectively
The numerical value of individual element needs to determine by sensor senses；The process of part provides excitation equivalent to sensory perceptual system,
Change clamping power, the clamping power for defining the moment 1 is E1=[e11 e12 … e1n], then clamping power change vector Δ E1=E1-
E0, with the progress of working angles, taking for new perception moment is fixed, and the clamping power perceived is respectively E2 E3 … Em, it is corresponding
The clamping power change vector of extension is respectively Δ E2 ΔE3 … ΔEm, the perception vector of whole working angles is Δ E=[Δs
E1 ΔE2 … ΔEm]T；Embodiment perceives the change for the perception point position clamping power that vector determines for step (a) before and after processing
Value；
S predicts object vector to perceive：Difference perceives moment (1~m) different perceived position (1~n) part residual stress deformations
Vector；Object vector S=[S1 S2 … Sm]T, each element represent it is different perception moment parts residual stress deflections, that is, exist
Difference perceives the residual stress deflection of moment release clamping parts diverse location；Wherein Si=[Si1 Si2 … Sin] represent
I perception the moment, the residual stress deformation values of part diverse location, it should be noted that each element value position not necessarily with
Perceived position is corresponding；It is residual stress deformation vector of the part along length center line that embodiment, which perceives prediction object vector,；
f:Δ E → S is to perceive the mapping relations that vector arrives object vector；The mapping relations by perceive vector solve target to
Amount, so as to realize that the perception to residual stress deformation is predicted；The mapping relations pass through theory deduction, finite element simulation or intelligence
Algorithm means obtain；Embodiment obtains the mapping relations using the means of finite element simulation；
(b) solution of forecast model is perceived；
The solution perceived for the deformation of n times indeterminate mounting and clamping system residual stress, has following deformation in different superfluous constraint points
Equation of comptability group：
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In formula:
eiRepresent the changing value of restraining force in each superfluous constraint；
δij(i=1,2,3 ..., n；J=1,2,3 ..., n；) statically determinate structure is represented in ejDuring=1 independent role, along eiThe position in direction
Move；
ΔiMStatic determinacy based structures are represented under residual stress independent role, along eiThe displacement in direction；
Thus, the solution formula of the indeterminate clamping structure sensor model of n times has just been obtained：
ΔM=-δ e (3)
In formula:
ΔM=[Δ1M Δ2M ΔnM]T；E=[e1 e2 … en]；
Residual stress deformation after parts fixation unloading is equal to the counter-force independent role for perceiving point clamping power changing value on part
Caused deformation, that is, obtain the deformation state of part；Deformation state now is that the residual stress after parts fixation unloading becomes
Shape value.
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| CN109635365A (en) * | 2018-11-22 | 2019-04-16 | 中国航发沈阳黎明航空发动机有限责任公司 | A kind of process of control casing cutting parts deformation |
| CN109765841A (en) * | 2019-01-09 | 2019-05-17 | 西北工业大学 | The space-time mapping method of online monitoring data and part Working position |
| CN110695725A (en) * | 2019-09-09 | 2020-01-17 | 北京航空航天大学 | Aviation thin-wall part tool and using method thereof |
| CN110919459A (en) * | 2019-12-06 | 2020-03-27 | 沈阳航空航天大学 | Method for detecting influence of clamping force on machining deformation of thin-wall part |
| CN111880477A (en) * | 2020-07-30 | 2020-11-03 | 南京航空航天大学 | Machining deformation prediction method integrating mechanism model and learning model |
| CN112014016A (en) * | 2020-07-30 | 2020-12-01 | 南京航空航天大学 | Method and device for accurately measuring deformation force in part machining process |
| CN112926152A (en) * | 2021-02-15 | 2021-06-08 | 西北工业大学 | Accurate control and optimization method for clamping force of thin-walled part driven by digital twin |
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