A Coupled Model for the Prediction of Surface Variation in Face Milling Large-Scale Workpiece With Complex Geometry
A Coupled Model for the Prediction of Surface Variation in Face Milling Large-Scale Workpiece With Complex Geometry
复制标题
复杂几何形状大型工件面铣表面变化预测的耦合模型
DOI：
10.1115/1.4042188
复制
发表时间：
2019-03
期刊：
影响因子：
--
通讯作者：
Xi Li-Feng
中科院分区：
文献类型：
--
作者：
Liu Shun;Jin Sun;Zhang Xue-Ping;Chen Kun;Tian Ang;Xi Li-Feng
端面铣削通常会产生表面质量的变化，对于具有复杂表面几何形状的大型零件（如气缸体，发动机缸盖和阀体）的铣削尤为严重。因此，表面变化是加工参数选择和部件使用性能（如密封、能耗和排放）的重要指标。一个有效的和全面的数值模式是非常需要的预测整个表面的表面变化。提出了一种基于abaqus和matlab数据集成迭代更新有限元模型的耦合数值模拟方法，用于预测大型复杂曲面零件端铣加工引起的表面变化。利用该耦合模型，考虑动态铣削力、铣削轨迹的螺旋曲线和间歇旋转接触特性等面铣加工过程，可以成功地模拟大尺寸曲面的三维变化。最后用有限元迭代分析得到的点云数据表示表面变化，并通过铣削实验进行验证。实测结果与预测结果的对比表明，新的预测方法能较好地模拟复杂组分的表面变化。基于验证模型，进行了一组分析，以评估局部刚度非均匀化和铣削力的变化对加工表面变化的影响。它表明，具有表面峰和凹的表面变化与局部刚度非均匀化密切相关，尤其是在进给方向上。该耦合预测方法为研究大型复杂零件的面形变化提供了一种理论和有效的方法。
Face milling commonly generates surface quality of variation, is especially severe for milling of large-scale components with complex surface geometry such as cylinder block, engine head, and valve body. Thus surface variation serves as an important indicator both for machining parameter selection and components' service performance such as sealing, energy consumption, and emission. An efficient and comprehensive numerical model is highly desired for the prediction of surface variation of entire surface. This study proposes a coupled numerical simulation method, updating finite element (FE) model iteratively based on integration of data from abaqus and matlab, to predict surface variation induced by face milling of large-scale components with complex surfaces. Using the coupled model, three-dimensional (3D) variation of large-scale surface can be successfully simulated by considering face milling process including dynamic milling force, spiral curve of milling trajectory, and intermittently rotating contact characteristics. Surface variation is finally represented with point cloud from iterative FE analysis and verified by face milling experiment. Comparison between measured and predicted results shows that the new prediction method can simulate surface variation of complex components well. Based on the verified model, a set of analyses are conducted to evaluate the effects of local stiffness nonhomogenization and milling force variation on machined surface variation. It demonstrates that surface variation with surface peaks and concaves is strongly correlated with local stiffness nonhomogenization especially in feed direction. And thus the coupled prediction method provides a theoretical and efficient way to study surface variation induced by face milling of large-scale complex components.
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DOI：
10.1016/j.procir.2015.03.075
发表时间：
2015
期刊：
Procedia CIRP
影响因子：
--
作者：
C. Felhő;B. Karpuschewski;J. Kundrák
通讯作者：
C. Felhő;B. Karpuschewski;J. Kundrák
DOI：
10.1007/s00170-013-5347-5
发表时间：
2014-02
期刊：
The International Journal of Advanced Manufacturing Technology
影响因子：
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DOI：
10.1016/j.procir.2015.02.165
发表时间：
2015
期刊：
Procedia CIRP
影响因子：
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作者：
H. D. Carvalho;J. Gomes;M. Schmidt;Vitor L.C. Brandão
通讯作者：
H. D. Carvalho;J. Gomes;M. Schmidt;Vitor L.C. Brandão
DOI：
10.1115/1.1828055
发表时间：
2005-02
影响因子：
4
作者：
M. Wan;Weihong Zhang;K. Qiu;T. Gao;Yonghong Yang
通讯作者：
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DOI：
10.1016/j.ijmachtools.2013.06.001
发表时间：
2013-10-01
影响因子：
14
作者：
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通讯作者：
Wang, Zhong-Qi