CN114707387A - Aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress - Google Patents
Aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress Download PDFInfo
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- CN114707387A CN114707387A CN202210441947.0A CN202210441947A CN114707387A CN 114707387 A CN114707387 A CN 114707387A CN 202210441947 A CN202210441947 A CN 202210441947A CN 114707387 A CN114707387 A CN 114707387A
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Abstract
The invention relates to the technical field of aluminum alloy processing, and provides an aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress, which comprises the following steps: constructing an aluminum alloy three-dimensional milling model without initial residual stress; determining a residual stress standard of milling; aluminum alloy milling single-factor simulation and multi-factor orthogonal simulation without initial residual stress; determining the influence rule of each milling parameter on the maximum residual stress of milling based on the single-factor simulation experiment result; judging the influence primary and secondary relation of each milling parameter on the maximum residual stress of milling based on the multi-factor orthogonal simulation experiment result to obtain a milling parameter optimization scheme for primarily optimizing the milling parameters; pre-adding initial residual stress to the aluminum alloy for milling simulation; and optimizing the milling parameters of the aluminum alloy for pre-adding the initial residual stress. The method can enable the simulation process to more accurately reflect the actual condition of the workpiece, reduce the complexity and cost of experimental operation and improve the machining precision of the aluminum alloy structural member.
Description
Technical Field
The invention relates to the technical field of aluminum alloy processing, in particular to an aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress.
Background
The demand for monolithic structures in the aerospace industry has become more stringent in recent years. The aluminum alloy is widely applied to aerospace due to the characteristics of small density, high specific strength, good corrosion resistance and the like. Most wrought aluminum alloys commonly used in the aerospace industry are 2000-series alloys and 7000-series alloys. The 7055 aluminum alloy is a novel aluminum alloy obtained by reducing the contents of Fe and Si and increasing the contents of Zn and Cu on the basis of 7050, has high strength and high fracture toughness, and is widely applied to airbus A380 and Boeing 747 airplanes as an integral structural component such as a wing lower wall plate, a truss and the like.
The integral structural member has the characteristics of complex structure, high material removal rate and poor rigidity, residual stress can be generated in the structural member under the influence of various factors such as clamping force, milling heat and the like in the machining process, the warping, bending and twisting of a workpiece or mixed deformation of the warping, bending and twisting or the mixed deformation of the three are caused in the releasing process, and the yield of the integral structural member is seriously influenced. Meanwhile, deformation caused by release of residual stress in the service process can bring serious potential safety hazards to the airplane. Before actual machining, the actual condition of the workpiece is often simulated through simulation to obtain optimized machining parameters. In the existing simulation technology of aluminum alloy machining, some simulation technologies consider initial residual stress for simulation, but the simulation technologies only aim to determine final residual stress and predict machining deformation under existing machining parameters when a workpiece has the initial residual stress, and the influence of the initial residual stress is not considered for optimizing the aluminum alloy machining parameters. Therefore, the existing technology for optimizing the aluminum alloy processing parameters by using simulation does not consider initial residual stress, so that the simulation precision is low, the actual condition of a workpiece is difficult to reflect, the yield of the aluminum alloy structural part processed under the simulated processing parameters is low, potential safety hazards are brought to the application process, and the complexity and the cost of experimental operation are increased.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the aluminum alloy milling parameter optimization method for carrying out simulation by pre-adding the initial residual stress, which can enable the simulation process to more accurately reflect the actual condition of a workpiece, reduce the complexity and cost of experimental operation and improve the processing precision of the integral structural member of the aluminum alloy.
The technical scheme of the invention is as follows:
an aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress is characterized by comprising the following steps;
step 1: constructing aluminum alloy three-dimensional milling model without initial residual stress
Step 2: determining a residual stress standard of milling; the residual stress standard is the maximum allowable residual stress;
and step 3: aluminum alloy milling simulation without initial residual stress
Designing a single-factor simulation experiment scheme and a multi-factor orthogonal simulation experiment scheme by taking milling parameters as independent variables, and performing aluminum alloy milling simulation by adopting finite element simulation software to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece without initial residual stress in each simulation experiment;
and 4, step 4: analysis of simulation results without initial residual stress
Respectively drawing the single-factor simulation experiment result by taking each milling parameter as a horizontal axis and the maximum residual stress of milling as a vertical axis, and determining the influence rule of each milling parameter on the maximum residual stress of milling; judging the influence primary and secondary relation of each milling parameter on the maximum residual stress of milling based on range analysis on the multi-factor orthogonal simulation experiment result, obtaining a milling parameter optimization scheme by combining the influence rule and the residual stress standard, and performing primary optimization on the milling parameters by adopting the milling parameter optimization scheme;
and 5: aluminum alloy milling simulation with pre-applied initial residual stress
Pre-applying initial residual stress to the aluminum alloy three-dimensional milling model without the initial residual stress, and performing aluminum alloy milling simulation by adopting the primarily optimized milling parameters to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece after the initial residual stress is pre-applied;
step 6: aluminum alloy milling parameter optimization for pre-initial residual stress
Comparing the difference between the maximum residual stress of the milling process on the aluminum alloy workpiece after the initial residual stress is pre-applied and the residual stress standard, optimizing the milling parameters again by adopting the milling parameter optimization scheme, simulating the aluminum alloy milling by adopting the milling parameters which are re-optimized, and if the maximum residual stress of the milling process on the aluminum alloy workpiece under the milling parameters which are re-optimized after the initial residual stress is pre-applied does not reach the target, continuing to optimize again; and if the target is reached, the optimized milling parameters are the final milling parameters.
Further, in the step 1, the aluminum alloy three-dimensional milling model comprises a workpiece model and a milling cutter model; the workpiece model is divided into a cutting layer, a transition layer and a substrate layer, and the selected material is aluminum alloy; the milling cutter model is characterized in that the front angle, the rear angle, the helical angle and the number of cutting edges of a cutter are set, and the cutter is selected to be a hard alloy milling cutter.
Further, in step 3, the milling parameters include milling speed, feed per tooth, milling depth and milling width, and the number of experimental points selected by each milling parameter is greater than 3.
Further, in step 3, the finite element simulation software is ANSYS.
Further, in the step 5, the initial residual stress is obtained by using an x-ray diffraction method for the actual plate.
Further, in the step 5, the pre-initial residual stress is applied to each node of the aluminum alloy workpiece.
The beneficial effects of the invention are as follows:
according to the invention, the aluminum alloy milling parameters are optimized by carrying out aluminum alloy milling simulation by pre-adding the initial residual stress, so that the simulation precision can be improved, the actual condition of the workpiece can be reflected more accurately in the simulation process, the complexity and the cost of experimental operation are reduced, the machining precision of the whole aluminum alloy structural member under the optimized milling parameters is higher, the yield of the aluminum alloy structural member is improved, and the potential safety hazard of the aluminum alloy structural member in the application process is eliminated.
Drawings
FIG. 1 is a flow chart of the method for optimizing parameters in aluminum alloy milling simulated by pre-applying initial residual stress according to the present invention.
Fig. 2 is a stress cloud graph of an aluminum alloy workpiece under milling parameters preliminarily optimized without initial residual stress in the process of optimizing the milling parameters of 7055 aluminum alloy by using the aluminum alloy milling parameter optimization method for simulating pre-initial residual stress according to the embodiment of the present invention.
Fig. 3 is a stress cloud diagram of an aluminum alloy workpiece under milling parameters preliminarily optimized after preliminary residual stress is pre-applied in the process of optimizing the milling parameters of 7055 aluminum alloy by the aluminum alloy milling parameter optimization method for simulating pre-applied initial residual stress according to the embodiment of the present invention.
Fig. 4 is a stress cloud diagram of an aluminum alloy workpiece under milling parameters that are optimized again after initial residual stress is pre-applied in the process of optimizing the milling parameters of 7055 aluminum alloy by the aluminum alloy milling parameter optimization method for simulating pre-initial residual stress according to the embodiment of the present invention.
Detailed Description
The invention will be further described with reference to the accompanying drawings and specific embodiments.
As shown in FIG. 1, the method for optimizing the milling parameters of the aluminum alloy simulated by pre-adding the initial residual stress comprises the following steps;
step 1: constructing aluminum alloy three-dimensional milling model without initial residual stress
Step 2: determining a residual stress standard of milling; the residual stress standard is the maximum allowable residual stress;
and step 3: aluminum alloy milling simulation without initial residual stress
Designing a single-factor simulation experiment scheme and a multi-factor orthogonal simulation experiment scheme by taking milling parameters as independent variables, and performing aluminum alloy milling simulation by adopting finite element simulation software to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece without initial residual stress in each simulation experiment;
and 4, step 4: analysis of simulation results without initial residual stress
Respectively drawing the single-factor simulation experiment result by taking each milling parameter as a horizontal axis and the maximum residual stress of milling as a vertical axis, and determining the influence rule of each milling parameter on the maximum residual stress of milling; judging the influence primary and secondary relation of each milling parameter on the maximum residual stress of milling based on range analysis on the multi-factor orthogonal simulation experiment result, obtaining a milling parameter optimization scheme by combining the influence rule and the residual stress standard, and performing primary optimization on the milling parameters by adopting the milling parameter optimization scheme;
and 5: aluminum alloy milling simulation with pre-applied initial residual stress
Pre-applying initial residual stress to the aluminum alloy three-dimensional milling model without the initial residual stress, and performing aluminum alloy milling simulation by adopting the primarily optimized milling parameters to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece after the initial residual stress is pre-applied;
step 6: aluminum alloy milling parameter optimization for pre-initial residual stress
Comparing the difference between the maximum residual stress of the milling process on the aluminum alloy workpiece after the initial residual stress is pre-applied and the residual stress standard, optimizing the milling parameters again by adopting the milling parameter optimization scheme, simulating the aluminum alloy milling by adopting the milling parameters which are re-optimized, and if the maximum residual stress of the milling process on the aluminum alloy workpiece under the milling parameters which are re-optimized after the initial residual stress is pre-applied does not reach the target, continuing to optimize again; and if the target is reached, the optimized milling parameters are the final milling parameters.
In the embodiment, the aluminum alloy three-dimensional milling model comprises a workpiece model and a milling cutter model; the workpiece model is divided into a chip layer, a transition layer and a substrate layer, and the selected material is aluminum alloy; the milling cutter model is characterized in that a front angle, a rear angle, a spiral angle and the number of cutting edges of a cutter are set, and the cutter is selected to be a hard alloy milling cutter. The milling parameters comprise milling speed, feeding amount of each tooth, milling depth and milling width, and the number of experimental points selected by each milling parameter is more than 3. The pre-initial residual stress can be applied to each node of the aluminum alloy workpiece, so that the residual stress at any position of the plate can be accurately applied.
In this embodiment, the aluminum alloy is 7055 aluminum alloy, and the working principle of the present invention is described below with reference to the accompanying drawings:
(1) constructing a 7055 aluminum alloy three-dimensional milling model without initial residual stress:
a. modeling: establishing an aluminum alloy three-dimensional milling model by using a DM module of finite element software ANSYS, wherein a workpiece is a cuboid plate with the size of 60mm multiplied by 20mm multiplied by 15mm, and is divided into a cutting layer, a transition layer and a substrate layer; the cutter is a three-tooth end mill with the diameter of 12mm and the helical angle of 30 degrees;
b. importing a model: selecting an Explicit Dynamics module in workbench of finite element software ANSYS, and introducing the built milling model into a Geometry sub-module under the module;
c. definition of materials: establishing 7055 aluminum alloy and hard alloy in an Engineering Data submodule, defining the density, elasticity (Young modulus, Poisson ratio), plasticity and failure of the material, and specially setting the plasticity and the failure as Johnson-Cook;
d. grid division: the workpiece material was defined as 7055 aluminum alloy and the tool material as cemented carbide in the Model sub-module. Meshing the cutter and the workpiece by using a tetrahedral mesh: defining the grid size of a cutting layer of a workpiece to be 0.5mm, and the grid size of a basal layer to be 2 mm; the size of the cutter grid is 2 mm;
e. setting a contact pair: inserting Connections into the Model, and establishing body-interaction by taking a cutting edge of the cutter as a main surface and a chip layer as a slave surface; establishing a body-interaction by taking the rear cutter face as a main face and the transition layer as a secondary face; setting the friend probability to be 0.3 and the Dynamic probability to be 0.1;
f. setting analysis step length and boundary conditions: setting step time to be 0.01s in Analysis Setting of a Model submodule; fixing the bottom of the plate; establishing a cylindrical coordinate by taking a central shaft of the milling cutter as a Z axis, and setting the rotating speed of the cutter by taking the cylindrical coordinate as a reference; setting the initial speed (feeding speed) of the cutter by taking the overall coordinate as a reference;
g. and submitting the task to solve.
(2) And determining the standard of the residual stress of the milling machining to be +/-24 MPa.
(3) And setting a single-factor simulation experiment scheme and a multi-factor orthogonal experiment scheme by taking the milling parameters as independent variables. And (3) returning to the workbench main interface, copying to obtain the modules in the step (1) with the same number as the experimental scheme, setting the milling depth and the milling width in the step a of each module according to the experimental scheme, setting the milling speed and the feeding amount of each tooth in the step f, submitting the tasks, and obtaining the maximum residual stress of the milling process corresponding to each simulation experiment.
(4) Respectively drawing the single-factor simulation experiment result by taking each milling parameter as a horizontal axis and the maximum residual stress of milling as a vertical axis, and determining the influence rule of each milling parameter on the maximum residual stress of milling; and judging the influence primary and secondary relation of each milling parameter on the maximum residual stress of milling based on range analysis on the multi-factor orthogonal simulation experiment result, obtaining a milling parameter optimization scheme by combining the influence rule and the residual stress standard, and performing primary optimization on the milling parameters by adopting the milling parameter optimization scheme.
In this embodiment, by analyzing the single-factor simulation experiment result, the rule of the influence of each milling parameter on the maximum residual stress of the milling process is obtained as follows: the maximum residual stress increases with increasing milling speed, with increasing feed per tooth, with increasing milling depth, with increasing milling width (less upward trend); the method comprises the following steps of carrying out range analysis on a multi-factor orthogonal simulation experiment result to obtain a primary and secondary relation of influence of each milling parameter on the maximum residual stress of milling: milling speed > feed per tooth > milling depth > milling width). In this embodiment, a milling parameter optimization scheme is obtained by combining the primary and secondary relationships, the influence rule and the residual stress standard, the milling parameter optimization scheme is adopted to perform preliminary optimization on the milling parameters, and the 7055 aluminum alloy milling simulation without initial residual stress is performed by adopting the preliminarily optimized milling parameters, so that an obtained stress cloud chart is shown in fig. 2. As can be seen from FIG. 2, the residual stress of the 7055 aluminum alloy under the milling parameters preliminarily optimized without the initial residual stress is-16.461-23.802 MPa, and the standard of the residual stress is achieved. In the milling parameter optimization scheme, the milling parameters are optimized according to the primary-secondary relation, only one milling parameter can be optimized, a plurality of milling parameters can also be comprehensively optimized, the milling parameters are optimized according to the influence rule, and the residual stress standard is used as the optimization target.
(5) And (3) acquiring initial residual stress of the actual aluminum alloy plate by adopting an x-ray diffraction method. And exporting the input files without the initial residual stress milling simulation, and respectively applying the initial residual stress in each input file. Importing each input file into a workbench to submit a task, and obtaining a milling maximum residual stress cloud picture on the aluminum alloy workpiece under the milling parameters preliminarily optimized after the initial residual stress is pre-added, as shown in fig. 3.
(6) Comparing the difference between the maximum residual stress of the milling process on the aluminum alloy workpiece after the initial residual stress is pre-applied and the residual stress standard, optimizing the milling parameters again by adopting the milling parameter optimization scheme, simulating the aluminum alloy milling by adopting the milling parameters which are re-optimized, and if the maximum residual stress of the milling process on the aluminum alloy workpiece under the milling parameters which are re-optimized after the initial residual stress is pre-applied does not reach the target, continuing to optimize again; and if the target is reached, the optimized milling parameters are the final milling parameters. In this embodiment, a cloud of the maximum residual stress of the milling process of the aluminum alloy workpiece under the milling parameters optimized again after the initial residual stress is pre-applied is shown in fig. 4.
In fig. 3, the maximum residual stress of the aluminum alloy workpiece in the milling process under the milling parameters preliminarily optimized after the initial residual stress is pre-applied is-22.881-26.665 MPa, and the residual stress standard cannot be met, so that the maximum residual stress of the aluminum alloy workpiece in the milling process becomes large after the initial residual stress is pre-applied, and the milling parameters need to be optimized again. In fig. 4, the maximum residual stress of the aluminum alloy workpiece in the milling process under the milling parameters optimized again after the initial residual stress is pre-applied is-23.715-15.911 MPa, so that the maximum residual stress of the aluminum alloy workpiece in the milling process under the milling parameters optimized again is reduced, the milling parameters finally obtained by optimization in the follow-up process can greatly improve the processing precision of the aluminum alloy integral structural member, improve the yield of the aluminum alloy structural member, and eliminate the potential safety hazard of the aluminum alloy structural member in the application process.
It is to be understood that the above-described embodiments are only some of the embodiments of the present invention, and not all of the embodiments. The above examples are only for explaining the present invention and do not constitute a limitation to the scope of protection of the present invention. All other embodiments, which can be derived by those skilled in the art from the above-described embodiments without any creative effort, namely all modifications, equivalents, improvements and the like made within the spirit and principle of the present application, fall within the protection scope of the present invention claimed.
Claims (6)
1. An aluminum alloy milling parameter optimization method for simulating by pre-adding initial residual stress is characterized by comprising the following steps;
step 1: constructing aluminum alloy three-dimensional milling model without initial residual stress
Step 2: determining a residual stress standard of milling; the residual stress standard is the maximum allowable residual stress;
and step 3: aluminum alloy milling simulation without initial residual stress
Designing a single-factor simulation experiment scheme and a multi-factor orthogonal simulation experiment scheme by taking milling parameters as independent variables, and performing aluminum alloy milling simulation by adopting finite element simulation software to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece without initial residual stress in each simulation experiment;
and 4, step 4: analysis of simulation results without initial residual stress
Respectively drawing the single-factor simulation experiment result by taking each milling parameter as a horizontal axis and the maximum residual stress of milling as a vertical axis, and determining the influence rule of each milling parameter on the maximum residual stress of milling; judging the influence primary and secondary relation of each milling parameter on the maximum residual stress of milling based on range analysis on the multi-factor orthogonal simulation experiment result, obtaining a milling parameter optimization scheme by combining the influence rule and the residual stress standard, and performing primary optimization on the milling parameters by adopting the milling parameter optimization scheme;
and 5: aluminum alloy milling simulation with pre-applied initial residual stress
Pre-applying initial residual stress to the aluminum alloy three-dimensional milling model without the initial residual stress, and performing aluminum alloy milling simulation by adopting the primarily optimized milling parameters to obtain the maximum residual stress of milling processing on the aluminum alloy workpiece after the initial residual stress is pre-applied;
step 6: aluminum alloy milling parameter optimization for pre-initial residual stress
Comparing the difference between the maximum residual stress of the milling process on the aluminum alloy workpiece after the initial residual stress is pre-applied and the residual stress standard, optimizing the milling parameters again by adopting the milling parameter optimization scheme, simulating the aluminum alloy milling by adopting the milling parameters which are re-optimized, and if the maximum residual stress of the milling process on the aluminum alloy workpiece under the milling parameters which are re-optimized after the initial residual stress is pre-applied does not reach the target, continuing to optimize again; and if the target is reached, the optimized milling parameters are the final milling parameters.
2. The method for optimizing the milling parameters of the aluminum alloy by pre-adding the initial residual stress for simulation as recited in claim 1, wherein in the step 1, the three-dimensional milling model of the aluminum alloy comprises a workpiece model and a milling cutter model; the workpiece model is divided into a cutting layer, a transition layer and a substrate layer, and the selected material is aluminum alloy; the milling cutter model is characterized in that a front angle, a rear angle, a spiral angle and the number of cutting edges of a cutter are set, and the cutter is selected to be a hard alloy milling cutter.
3. The method for optimizing the milling parameters of the aluminum alloy by pre-adding the initial residual stress for simulation as recited in claim 1, wherein in the step 3, the milling parameters comprise milling speed, feeding amount per tooth, milling depth and milling width, and the number of experimental points selected by each milling parameter is more than 3.
4. The method for optimizing milling parameters of aluminum alloy by pre-applying initial residual stress for simulation as recited in claim 1, wherein in said step 3, said finite element simulation software is ANSYS.
5. The method for optimizing the milling parameters of the aluminum alloy for simulating the pre-initial residual stress according to claim 1, wherein in the step 5, the initial residual stress is obtained by adopting an x-ray diffraction method on an actual plate.
6. The method for optimizing the milling parameters of the aluminum alloy by simulating the pre-initial residual stress according to claim 1, wherein in the step 5, the pre-initial residual stress is applied to each node of the aluminum alloy workpiece.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115584413A (en) * | 2022-09-05 | 2023-01-10 | 深圳市万泽中南研究院有限公司 | Machining parameter optimization method and nickel-based powder superalloy machine |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115584413A (en) * | 2022-09-05 | 2023-01-10 | 深圳市万泽中南研究院有限公司 | Machining parameter optimization method and nickel-based powder superalloy machine |
| CN115584413B (en) * | 2022-09-05 | 2024-05-14 | 深圳市万泽中南研究院有限公司 | Machining parameter optimization method |
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