考虑力致变形时变效应的薄壁构件侧铣切削力建模

doi:10.3901/JME.260434

摘要/Abstract

摘要： 铝合金薄壁件具有重量轻、整体刚性高等特点，在航空航天领域有着重要应用。由于薄壁件的侧壁和腹板厚度较薄，加工时铣削力是诱导产生加工误差的关键因素，为进一步揭示薄壁件铣削机理和优化切削工艺，准确预测切削力尤为重要。针对薄壁件弱刚性特征，提出了一种考虑力致变形效应的柔性铣削力预测模型，揭示了铣削力与挠度变形的耦合规律。根据Kirchhoff理论和铣削过程中工件变形引起的刀-工切触区域变化，建立了柔性铣削力预测模型和薄壁件挠度弯曲变形量有限元计算方法，表征了力与工件切触区的时变接触关系，并利用切削过程中产生的动态变形值迭代修正瞬时切削厚度，提升铣削力模型的预测精度。将预测结果和实验结果进行比较，该方法变形预测值的最大误差在0.012 mm以内，X、Y方向铣削力预测值的平均误差小于10%，验证了模型的准确性与有效性。所建立的切削力模型可为合理优化刀具结构和推荐工艺参数提供理论依据。

关键词: 薄壁件, 铣削力建模, 加工变形, Kirchhoff理论, 有限元计算

Abstract: Aluminum alloy thin-walled parts have important applications in the aerospace field due to their light weight and high overall rigidity. Due to the thin thickness of the side wall and web of thin-walled parts, the milling force during machining is a key factor inducing machining errors. In order to further reveal the milling mechanism of thin-walled parts and optimize the cutting process, it is particularly important to accurately predict the cutting force. Aiming at the weak stiffness characteristics of thin-walled parts, a flexible milling force prediction model considering the force-deformation effect is proposed, and the coupling law between milling force and deflection deformation is revealed. According to the Kirchhoff theory and the change of cutter-workpiece contact area caused by workpiece deformation in the milling process, a model of flexible milling force prediction and a finite element calculation method of deflection bending deformation of thin-walled parts are established, which characterize the time-varying contact relationship between the force and the workpiece contact area. The dynamic deformation values generated during the cutting process are used to iteratively correct the instantaneous cutting thickness and improve the prediction accuracy of the milling force model. Comparing the prediction results with the experimental results, the maximum error of the predicted deformation value of the proposed method is within 0.012 mm, and the average error of the milling force prediction in the X and Y directions is less than 10 %, which verifies the accuracy and effectiveness of the model. The established cutting force model can provide a theoretical basis for the reasonable optimization of tool structure and the recommendation of process parameters.

Key words: thin-walled parts, milling force modeling, machining deformation, Kirchhoff theory, finite element calculation

中图分类号:

TH161

夏伟, 刘献礼, 岳彩旭, 郭焱栋, 孙绍聪. 考虑力致变形时变效应的薄壁构件侧铣切削力建模[J]. 机械工程学报, 2026, 62(9): 430-446.

XIA Wei, LIU Xianli, YUE Caixu, GUO Yandong, SUN Shaocong. Modeling of Side Milling Cutting Force on Thin-walled Components Considering Time-varying Effect of Force-induced Deformation[J]. Journal of Mechanical Engineering, 2026, 62(9): 430-446.

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http://www.cjmenet.com.cn/CN/Y2026/V62/I9/430

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