Prediction of surface variation field in face milling via finite element model updating with considering force-deformation coupling
Prediction of surface variation field in face milling via finite element model updating with considering force-deformation coupling
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DOI：
10.1007/s00170-019-04448-w
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发表时间：
2019-11
期刊：
影响因子：
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通讯作者：
Shun Liu;Xueping Zhang;Sun Jin;Ang H. O. Tian;Kun-kun Chen;L. Xi
中科院分区：
文献类型：
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作者：
Shun Liu;Xueping Zhang;Sun Jin;Ang H. O. Tian;Kun-kun Chen;L. Xi
在大型非连续曲面零件的面铣加工中，有效地预测面形变化对于制定和控制加工工艺，保证表面质量具有重要意义。然而，传统的有限元分析方法对已加工表面误差的模拟范围远小于大型多齿面铣加工所需的模拟范围。为了解决这个问题，本文试图开发一种数值方法来估计加工表面误差的现场数据的基础上迭代有限元分析与切削轨迹重构。采用有限元模型修正法（FEMU），分析了铣削过程中切削力的变化和零件局部几何形状的差异对切削变形的影响。考虑瞬时切削力与切削变形的耦合作用，建立了柔性切削模型，预测了各切削时刻的残余切削量。在此基础上，提出了一种用修正的牛顿-拉夫逊法计算柔性切削系统平衡挠度和真实的剩余材料的子迭代格式。该仿真方法可普遍应用于大型多孔曲面零件，特别是柔性零件的面形变化场预测。
Effective prediction of surface variation is of great helpf for developing and controlling machining process to maintain surface quality during face milling of large-scale component with discontinuous surface. However, the simulation ranges of machined surface error in traditional finite element analyses are far less than those needed in characterization of large-scale face milling with multi-tooth cutter in order to maintain efficiency. To address this issue, this paper attempts to develop a numerical methodology to estimate the field data of machined surface error based on iterative finite element analysis integrated with cutting trajectory reconfiguration. Finite element model updating (FEMU) method is applied to analysis the cutting deformation in each cutting instant while considering both the cutting force variation in face milling and the locally geometrical differences of component. A flexible model is established to predict the residual cutting material in each cutting instant with considering the coupling effect between instantaneous cutting force and cutting deformation. And then a sub-iteration scheme is proposed to calculate the equilibrium deflection and the real residual material of flexible cutting system with a modified Newton-Raphson method. The proposed simulation methodology can be generally applied for predicting surface variation field in face milling of large-scale component with multi-holed surface, especially for flexible component.