Abstract
With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process.
Highlights
In order to improve the prediction accuracy of surface topography in the milling process for thin-walled parts, this paper proposes a surface topography prediction model considering the elastic deformation of thin-walled parts and the tool–workpiece contact considering the elastic deformation of thin-walled parts and the tool–workpiece contact relationship
Inthickness, the milling process of thin-walled parts, the topography is predicted workpiece under the current force action is obtained through the force–deformation couthe superposition of the workpiece surface profile and the deformation calculated by the pling model
In the milling process of thin-walled parts, the surface topography is predicted by the superposition of the workpiece surface profile and the deformation calculated by the cutting force
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. In the prediction model of surface topography considering plastic deformation in the side milling process, through experiments and sensitivity analysis, it was found that tool deflection is the key factor affecting roughness. Arizmendi [7] established a surface morphology prediction model considering tool geometry and installation error Since this model does not consider the influence of cutting force on surface texture, the best application effect is face milling. Chen [14] established the dynamic cutting forces model by considering the regeneration effect of tool run-out and axial drift, and proposed the surface topography simulation method based on the Z-map model. An effective cutting force calculation model is the basis of predicting the deformation and surface topography thin-walled parts. Convert the tangential force, dFt,i,j , radial force, dFr,i,j , and axial force, dFa,i,j , to the cutting force in the X, Y and Z directions, as: FX,i,j , FY,i,j , FZ,i,j
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