Finite Element Simulation of Bending Thin-Walled Parts and Optimization of Cutting Parameters
Abstract
:1. Introduction
2. Milling Parameters and Models of Bending Thin-Walled Parts
2.1. Basic Steps of Finite Element Analysis for Bending Thin-Walled Parts
2.2. Influence of Position Change of Milling Cutter in Circumferential Direction
2.3. Analysis of Machining Deformation Results
2.4. Influence of the Milling Cutter Position in the Z Direction on the Deformation
2.5. Influence of Cutting Parameters on the Deformation at the Maximum Deformation Point by Orthogonal Experiments
3. Single Factor Experiments in the Influence of Cutting Parameters on Machining Deformation
3.1. Influence of Milling Speed on Machining Deformation
3.2. Influence of Feed per Tooth on Machining Deformation
3.3. Influence of Axial Depth of Cutting on Machining Deformation
3.4. Influence of Radial Depth of Cutting on Machining Deformation
4. Conclusions
- (1)
- The maximum deformation point is determined to be R = 62 mm, θ = 180 degrees and Z = 72.5 mm, and the maximum radial deformation is 3.13%. Thus, it should be as far away from the point as possible in the process of machining.
- (2)
- Through orthogonal experiments, the optimal cutting parameter combination was selected as vc = 140 m/min, fz = 0.08 mm/tooth, ap = 2 mm and ae = 0.8 mm. Finally, the influence of each milling parameter on the machining deformation was studied.
- (3)
- The research shows that the radial depth of cutting has the greatest influence on the deformation of bending thin-walled parts, followed by the axial depth of cutting and the feed per tooth. The milling speed has little influence on the machining deformation of bending thin-walled parts.
- (1)
- In order to further reduce the deformation of bending thin-walled parts in the milling process, the cutting heat and tool wear between the tool and the workpiece in the milling process will be studied.
- (2)
- According to the shape characteristics of the parts, more scientific and reasonable clamping and supporting methods of bending thin-walled parts will be designed to control the deformation of parts.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Factors | Milling Speed vc (m/min) | Feed per Tooth fz (mm/tooth) | Axial Depth of Cutting ap (mm) | Radial Depth of Cutting ae (mm) |
---|---|---|---|---|
1 | 100 | 0.08 | 2 | 0.8 |
2 | 140 | 0.1 | 3 | 1.2 |
3 | 180 | 0.12 | 4 | 1.6 |
4 | 200 | 0.14 | 5 | 2 |
No. | Milling Speed vc (m/min) | Feed per Tooth fz (mm/tooth) | Axial Depth of Cutting ap (mm) | Radial Depth of Cutting ae (mm) | Milling Force Fymax (N) | Maximum Radial Deformation (mm) |
---|---|---|---|---|---|---|
1 | 100 | 0.08 | 2 | 0.8 | 56 | 0.046862 |
2 | 100 | 0.1 | 3 | 1.2 | 133 | 0.111297 |
3 | 100 | 0.12 | 4 | 1.6 | 247 | 0.206694 |
4 | 100 | 0.14 | 5 | 2 | 369 | 0.308786 |
5 | 140 | 0.08 | 3 | 1.6 | 158 | 0.132217 |
6 | 140 | 0.1 | 2 | 2 | 183 | 0.153138 |
7 | 140 | 0.12 | 5 | 0.8 | 101 | 0.084519 |
8 | 140 | 0.14 | 4 | 1.2 | 189 | 0.158159 |
9 | 180 | 0.08 | 4 | 2 | 231 | 0.193305 |
10 | 180 | 0.1 | 5 | 1.6 | 246 | 0.205857 |
11 | 180 | 0.12 | 2 | 1.2 | 127 | 0.106276 |
12 | 180 | 0.14 | 3 | 0.8 | 109 | 0.091213 |
13 | 220 | 0.08 | 5 | 1.2 | 128 | 0.107113 |
14 | 220 | 0.1 | 4 | 0.8 | 86 | 0.071966 |
15 | 220 | 0.12 | 3 | 2 | 287 | 0.240167 |
16 | 220 | 0.14 | 2 | 1.6 | 195 | 0.16318 |
Comprehensive Average Value | Milling Speed | Feed per Tooth | Axial Depth of Cutting | Radial Depth of Cutting |
---|---|---|---|---|
K1 | 0.1684 | 0.1199 | 0.008 | 0.07364 |
K2 | 0.132 | 0.1356 | 0.1437 | 0.12 |
K3 | 0.1492 | 0.1594 | 0.1575 | 0.17699 |
K4 | 0.1456 | 0.18 | 0.1766 | 0.2238 |
T | 0.0364 | 0.0601 | 0.052 | 0.15016 |
No. | Milling Speed vc (m/min) | Feed per Tooth fz (mm/tooth) | Axial Depth of Cutting ap (mm) | Radial Depth of Cutting ae (mm) | Radial Force Fymax (N) | Radial Deformation (mm) |
---|---|---|---|---|---|---|
1 | 100 | 0.08 | 2 | 0.8 | 54.9 | 0.045941 |
2 | 140 | 0.08 | 2 | 0.8 | 55 | 0.046025 |
3 | 180 | 0.08 | 2 | 0.8 | 55.2 | 0.046192 |
4 | 220 | 0.08 | 2 | 0.8 | 55.3 | 0.046276 |
5 | 140 | 0.1 | 2 | 0.8 | 65.54 | 0.054845 |
6 | 140 | 0.12 | 2 | 0.8 | 75.555 | 0.063226 |
7 | 140 | 0.14 | 2 | 0.8 | 85.21 | 0.071305 |
8 | 140 | 0.08 | 3 | 0.8 | 65.57 | 0.05485 |
9 | 140 | 0.08 | 4 | 0.8 | 74.2 | 0.062092 |
10 | 140 | 0.08 | 5 | 0.8 | 81.7 | 0.068368 |
11 | 140 | 0.08 | 2 | 1.2 | 90.2 | 0.075481 |
12 | 140 | 0.08 | 2 | 1.6 | 127.94 | 0.107113 |
13 | 140 | 0.08 | 2 | 2 | 167.83 | 0.140443 |
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Hailong, M.; Aijun, T.; Shubo, X.; Tong, L. Finite Element Simulation of Bending Thin-Walled Parts and Optimization of Cutting Parameters. Metals 2023, 13, 115. https://doi.org/10.3390/met13010115
Hailong M, Aijun T, Shubo X, Tong L. Finite Element Simulation of Bending Thin-Walled Parts and Optimization of Cutting Parameters. Metals. 2023; 13(1):115. https://doi.org/10.3390/met13010115
Chicago/Turabian StyleHailong, Ma, Tang Aijun, Xu Shubo, and Li Tong. 2023. "Finite Element Simulation of Bending Thin-Walled Parts and Optimization of Cutting Parameters" Metals 13, no. 1: 115. https://doi.org/10.3390/met13010115