Abstract: To improve the machining deformation prediction accuracy of thin-walled deep cavity parts,the deformation error caused by milling force was researched,and a machining deformation simulation method of thin-walled deep cavity parts based on dynamics analysis was proposed.By establishing dynamical equation of the tool and solving its key parameters,the motion state of arbitrary point on the tool could be obtained in the process of milling.Besides,the birth and death element method was adopted to simulate the material removal process.During the calculation of milling force,the dynamic response of milling force which caused by the deflection of both tool and workpiece was considered.Thus,instantaneous cutting thickness and overall milling force which considered the deformation feedback were calculated.The real-time variation of workpiece in the process and the deformation of workpiece lateral wall affected by the milling force were obtained.The accuracy of this simulation approach was verified by experiment.

Key words: finite element method, thin-walled deep cavity parts, machining deformation, dynamics simulation

摘要： 为了提高薄壁深腔零件侧壁加工变形的预测精度,对铣削力引起的侧壁让刀误差进行了研究,提出一种基于动力学分析的薄壁深腔零件加工变形有限元动态仿真方法。该方法通过建立刀具动力学方程,求解其中关键参数、得到铣削过程中刀具任意点运动状态,并采用生死单元法对被切削材料进行去除。在计算铣削力时考虑刀具/工件挠度变形对铣削力的动态响应,计算获得考虑让刀反馈的铣刀瞬时切削厚度及总体铣削力,最终得到零件加工过程的实时变化规律,以及在此铣削力影响下工件侧壁的变形量。通过实验验证了仿真方法的准确性。

关键词: 有限元法, 薄壁深腔零件, 加工变形, 动力学仿真