, New materials, new structures, new technology, more and more manufacturers of parts of the higher demand. With the continuous development of virtual manufacturing technology, simulation technology in the aviation industry more and more extensive applications. Simulation techniques can be divided into two types: geometric simulation and physical simulation.
known as the data or NC code driven, simulation of metal cutting in the cutting path and the process material is removed, allowing users an intuitive way to process planning to assess the reasonableness of the CNC machining process for checking whether there is interference. The main advantage of the geometric simulation validated the accuracy of processing, interference checking, machine parts to avoid the collision with the fixture and parts, to reduce the cut in part on the test of time. However,
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,
UGGs, there are still many problems in processing the geometric simulation can not be solved. For example, many difficult materials in processed prone to deformation, stress concentration, surface seismic lines and other quality problems, but due to the geometric simulation of machining parts is assumed to be rigid,
UGG NZ, without regard to the processing components such as temperature, material,
UGGs Clearance, or tool wear, etc. physical properties, so can not solve these problems. To solve such problems, but also to carry out physical simulation technology research, through the workpiece, tool, material properties and processing environment for the comprehensive analysis, the process of cutting force and temperature data.
studied in this paper the physical simulation, can help users to reasonably match the process parameters and tool, the CNC machining process optimization or provide solutions to reduce the cutting forces and deformation of parts and so on. All these have greatly reduced the expensive cutting tests, reducing processing costs, improve processing efficiency and machine utilization.
fact, the current market,
UGG Classic Tall, many of the physical simulation software such as ANSYS or DEFORM,
UGG Boots NZ, etc. These systems are the main object of work or professional research institutions, universities, their physical simulation software through the application of these theoretical studies, But the real business to conduct applied research in manufacturing and achieve results, but also rare. This article is based TWS (Third Wave Systems)'s AdvantEdge software tools, applications, and PM are two modules to carry out FEM comprehensive research and analysis. Which, AdvantEdge FEM is mainly used to optimize metal cutting process. In the process, can improve part quality and increase the material removal rate, extend tool life. Try using AdvantEdge FEM can reduce the number and cost cutting, fast to get the best processing parameters, so that rapid market-oriented products. AdvantEdge PM is mainly used for process analysis, especially for difficult materials,
UGG Boots NZ, processing materials, precious or cut can not do the test case for NC machining NC program optimization program or can provide customers with a trend of the results to help customers do the decision making process.
a mainly technical route
physical simulation because there are few in the industry can learn from successful experience, so I unit of the technical staff through a period of exploration, before deciding on a set of technologies for the enterprise line. In terms of aviation products, the first problem to be solved is the choice of processing parameters and processing quality. According to these technical difficulties can develop the following scenario.
(1) analysis of parts processing,
Boot Classic UGG, collecting the key position of parts processing parameters and operating conditions information.
(2) the physical simulation environment to build parts of the micro-cutting model, and enter the material properties and processing parameters and other information, analysis and calculation process to be part of cutting force, temperature, stress distribution and cutting state and other parameters, and accordingly concluded to be a preferred cutting parameters,
Boot UGG, a reasonable choice tool. This process is mainly using FEM analysis and the process shown in Figure 1.
Figure 1 FEM analysis process
(3) depending on the chosen processing parameters and tool preparation of CNC machining process.
(4) of the NC machining program for physical simulation. Key parameters by entering the machine,
UGG outlet store, part model, NC code and the processing environment parameters, optimizing the CNC machining process, to get part of macro processing force. Based on the results, in the part load balancing under the premise of not only the processing program can be adjusted, but also in the physical simulation environment, the NC program optimization. This process is mainly used for analysis and optimization of PM analysis process shown in Figure 2.
Figure 2 PM workflow
paragraph (2) and step (4) the physical simulation step is the focus of analysis. In the application process, to combine the characteristics of flexible use of parts, according to processing requirements, focused, targeted for analysis, not necessarily to completely follow the above steps.
FEM required information is relatively accurate, and the input parameters of the more complete analysis of the conclusions the closer the actual results. PM output result can be a general trend can be, but the NC program code and format requirements more stringent.
Second,
UGG outlet store,
Boot UGG Australia,
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, the simulation examples below
the author of a turbine disc lathe with an example for analysis (Figure 3), the material for the high-temperature alloy parts, spare parts easily deformed after processing, is a typical in difficult materials. As the actual processing allowance for each position and the cutting methods are not the same, are not the same processing parameters, requiring separate analysis.
3 part structure diagram
1. application of FEM optimized processing parameters
here only the parameters of the parts analysis processing example. FEM is to build parts of the microscopic model and finite element analysis model to analyze, so the analysis needs to be simplified microscopic model. Figure 4 Schematic diagram for the processing parameters. Table
1 for the preparation of three processing parameters.
shown in Figure 5,
Boot UGG, each ribbon diagram above that the temperature of processing state, following the curve, X direction (red curve) for the tangential components suffered Li, Y direction (green curve) as part of the axial force suffered.
analysis from three sets of parameters can be seen,
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, affecting parts of the surface temperature and organizations The main condition is the feed rate, feed faster, cutting tools and parts to be machined surface temperature is higher. Affect parts of the axial deformation of the force is cut deep, when from the 0.5mm depth of cut is reduced to 0.25mm, the axial cutting force is reduced by the 900N to 400N or so. Tangential force components suffered did not change significantly, values much smaller than the axial force. Figure 5 shows the simulation results only after the temperature and stress conditions, as well as parts and tool surface stress, strain contour and chip status, because of space reasons, it is not going to detail, all analysis of the conclusions are the choice of machining parameters and tool to provide a favorable data base.
2. application of CNC machining solutions to optimize PM
FEM analysis, the choice of machining parameters and tool can be used as the basis for NC programming. PM is on the NC machining program for analysis. Of the PM physical simulation, can be found in craft program in a pre-existing problems, timely correction of input data, re-define the simulation environment, until the program on technology and processing parameters to optimize satisfaction.
First, in order to verify the accuracy of PM analysis, the author to the scene to collect the turbine disk normal processing of the cutting line of equipment, cutting tools and machining parameters and other information, and with CNC machining parameters were analyzed. Figure 6 is a process of convergence Board cavity comparative analysis, the left diagram a, Fig c, Fig e, and Figure g reflects the common device processing conditions, the right side of Figure b, Figure d, f and Figure h is the map NC device processing conditions. Peak force in all directions compared in Table 2.
through the analysis shows that the forces generated by ordinary lathe CNC lathe generally higher than the force generated is larger, and is doubled. Lathe turning tool for machining process using molding,
UGG outlet, CNC lathe processing using a standard blade. Tool and parts forming a larger contact area, a large volume of material removed, the resulting force as well. The use of standard blades, can reasonably be distributed to the tool path to remove the margin more evenly,
UGG Classic Tall, so a more balanced force. Analysis results and the actual processing is the same conclusion.
staffing CNC programming process is often cut from the beginning to the end of the cutting is always a constant feed. PM optimizes NC program is mainly based on the uneven parts of the force, the feed rate optimization, and optimization of the feed, the results of the analysis required to determine the following parameters.
(1) optimize the site. The sites include the rapid feed and cutting parts,
UGGs Online,
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, etc. In general,
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, the technical staff will quickly set to feed parts of the G00, does not participate in the cutting, so do not need to do optimization. The cutting part of the optimization of the feed value can be determined in a period block.
(2) optimization part of the force range. After analyzing the original program, if there are problems, there will always be more obvious by the size of the force mutation position,
UGG Outlet Store, which is more sensitive to the location of parts,
UGG Boots NZ,
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, need to be further optimized. According to the analysis of the original program, in the optimization, you need to be part of the force a reasonable range, so the system will, according to the optimization of a given range of feed re-set, making the analysis out of the force curve figure is relatively stable.
(3) backward to optimize the value range. System according to the set to optimize the feed value, the maximum feed value should be greater than zero,
UGG Outlet Wrentham, otherwise it will not be optimized by setting the value. Figure 7 PM to optimize the interface into the NC program.
Figure 7 PM
NC program optimization interface to a turbine disk drive processing, for example, the tool path shown in Figure 8.
Figure 8 Example
tool path through the analysis of the cutting force curve, the red curve in Figure 9 below. According to the resulting cutting force, load balancing based on the principle of optimization, the optimized curve for the green curve. Can be seen, the optimized processing, not only to shorten the processing time, and cutting more balanced. Only from the numerical comparison,
UGG Discount Sale, the processing time reduced from 606s to 360s,
Boots UGG Australia, processing efficiency can be increased by 40%.
NC program after the application of PM analysis can not be optimized by adjusting the processing programs to change parts of the allowance, so that part of the force balance of the region. I for different parts of the lathe were analyzed and summed up the processing characteristics of car-based solutions.
(1) a straight line. Tool path for the horizontal or vertical lines, even at the margin, cutting parameters constant in the case, theoretically cutting load evenly. Therefore, according to the rigidity of parts, by reducing the feed rate and depth of cut to reduce the load, thereby reducing part distortion.
(2) slash. Tool path for the oblique straight line, even when the margin when the axial and tangential cutting force changed little, can be seen as the same. Take the knife slash the time needed to leave margin evenly, so cutting forces relatively stable. Diagonal passes, we should consider the rigidity of parts to choose the right way to take the knife.
(3) round. Rounded into convex and concave circular, in the rounded part, due to the amount of cutting and cutting angle changes,
UGGs Outlet, the cutting force will change a lot. Processing engine in the car wheel spoke panel, pay special attention, because at the concave corner, a large axial force, the weak long rigid plate convergence greater impact. Develop processing programs should be handled first round look at the margin, as smaller, rounded corners and then set the feed rate decreases, the normal cutting feed about 1 / 3.
(4) turning point. At the inflection point at the cutting larger, so prone to cutting force of the mutations. Moreover,
UGGs Clearance Boots, there is stress concentration at the inflection point, combined with cutting forces relatively large, so it is necessary to consider the rigidity of parts to choose treatment. Recommend programming,
UGG Australia NZ, try to choose the inflection point arc tool path method, and the inflection point in the processing at the margin before treatment.
Third, the conclusion
present, many still need to select the processing parameters to obtain cut-site test, test costs high, and unnecessary waste of resources. Aero-engine manufacturing is an urgent need physical simulation technology application and promotion. This paper proposes a combination of FEM and PM turning two physical simulation module for the analysis process, the problem of geometric simulation solve many problems. The proposed method with parameters of function, can be cutting speed, feed rate, rake angle and cutting edge radius and other parameters of the study, and program development for CNC machining, CNC machining process optimization, improve part quality, accuracy and so has a practical significance.
but also rare. This article is based TWS UGGs
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