Optimization of Thin-walled Part Milling Parameters Based on Finite Element and Orthogonal Dominance Analysis

Hu, Quanwei

doi:10.3901/jme.2013.21.176

Cited by 5 publications

(2 citation statements)

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“…For the problems of workpiece machining deformation and surface quality, Hu et al 3 proposed a finite element orthogonal dominance analysis method, the method is to use orthogonal test design to guide finite element milling, so as to optimize milling machining parameters and reduce the deformation generated in the machining of thin-walled parts. Cong et al 4 proposed a residual stress deformation simulation prediction method based on the mapping of Tianjin University of Technology and Education, Tianjin, China working conditions and thin shell stress fitting, and optimized milling parameters, and the results showed that the method can effectively predict the residual stress deformation in thin-walled parts machining.…”

Section: Introductionmentioning

confidence: 99%

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Zhan,

Jin,

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Thin-walled parts are characterized by weak rigidity and are very prone to deformation during machining, which directly affects the machining accuracy and performance of the parts, so controlling the machining deformation of thin-walled parts is an urgent process problem to be solved. To address such problems, this paper proposes a flatness control machining method based on ice holding of workpieces. The method uses frozen suction cups to solidify liquid water to achieve stress-free clamping of workpieces. We conducted a low-temperature tensile test to investigate the low-temperature mechanical properties of the material. Comparative tests of ice-free and low-temperature ice-fixed milling were conducted to compare and analyze the changes of flatness and milling force in the two working conditions, to investigate the influence of machining parameters on the flatness of thin-walled parts, and to reveal the mechanism of low-temperature milling of ice-fixed workpieces. In addition, the low-temperature milling performance of titanium/aluminum alloy based on ice-fixation was compared. The results show that TC4 has good plasticity, high flexural strength ratio and strong resistance to deformation at low temperatures. Compared with no ice-holding, ice-holding machining effectively improves the flatness of the workpiece, and the order of the machining parameters affecting flatness is: feed rate > milling depth > spindle speed. The milling forces under ice-holding conditions were all greater than those without ice holding. The stiffness and hardness, resistance to damage and deformation of titanium alloy at low temperature are greater than those of aluminum alloy. This method provides a new method for high-precision machining of thin-walled parts.

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Section: Introductionmentioning

confidence: 99%

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Zhan,

Jin,

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…Through representative experiments, the orthogonal experimental method can evaluate the impact of each orthogonal factor on the results, determine the order of influence, and obtain the factor combination for the relatively best results [24]. There are many influence parameters in the process of optimizing the milling deformation.…”

Section: Orthogonal Experimental Design For the Milling Of Thin-walle...mentioning

confidence: 99%

Analysis and Optimization of Milling Deformations of TC4 Alloy Thin-Walled Parts Based on Finite Element Simulations

et al. 2023

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TC4 (DIN3.7164/5) alloy thin-walled parts are widely used in aviation and aerospace industries. However, due to their special structure, shape and poor machinability, large milling forces and milling deformation often occur in the milling process, which cannot guarantee the machining quality and accuracy. The milling processing parameters and milling geometric parameters have a significant impact on the milling force and the deformation, and optimization of the influence factors of milling deformations is important for milling quality. Considering that performing milling experiments under multiple conditions is often costly and time-consuming, this paper provides a finite-element-simulation-based method to study effects of the factors on the forces and deformations during milling thin-walled parts. Firstly, using ABAQUS, a finite element simulation model of the milling process of thin-walled parts is established. Additionally, an orthogonal experimental scheme is designed for optimization of the milling parameters, so as to determine the optimized experimental scheme, and then the optimized experimental scheme is verified to reduce the milling force and deformation by finite element simulations. The optimal parameters for a minimal milling force are a spindle speed of 2000 r/min, a feed rate per tooth of 0.04 mm/z, a milling depth of 1.6 mm, a milling width of 1 mm, a diameter of 6 mm, a rake angle of 20°, a tilt angle of 45°, and two teeth. Similarly, the optimal parameters for minimal node deformations are a spindle speed of 4800 r/min, a feed rate per tooth of 0.18 mm/z, a milling depth of 1 mm, a milling width of 1 mm, a diameter of 16 mm, a rake angle of 20°, a tilt angle of 40°, and four teeth. In addition, this paper uses an optimization algorithm to fit the empirical function with a certain practical value, which can provide a reference for the machining of TC4 titanium alloy. By doing so, we can optimize the milling parameters to obtain the desired machining quality and accuracy, while also saving on time and resources.

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Simulation of the deformation caused by the machining cutting force on thin-walled deep cavity parts

Liu

Shao

et al. 2017

Int J Adv Manuf Technol

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Optimization of Thin-walled Part Milling Parameters Based on Finite Element and Orthogonal Dominance Analysis

Cited by 5 publications

References 0 publications

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Analysis and Optimization of Milling Deformations of TC4 Alloy Thin-Walled Parts Based on Finite Element Simulations

Simulation of the deformation caused by the machining cutting force on thin-walled deep cavity parts

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