薄壁结构件毛坯去应力分析与铣削加工变形有限元模拟研究

徐飞飞; 刘其广; 吕杰; 金鑫

doi:10.13433/j.cnki.1003-8728.20230287

薄壁结构件毛坯去应力分析与铣削加工变形有限元模拟研究

doi: 10.13433/j.cnki.1003-8728.20230287

北京航空材料研究院股份有限公司, 北京 100095

详细信息

作者简介:
徐飞飞, 工程师, xufeifei0212@163.com

中图分类号: TG156
计量
- 文章访问数: 73
- HTML全文浏览量: 32
- PDF下载量: 15
- 被引次数: 0
出版历程
- 收稿日期: 2023-03-17
- 刊出日期: 2024-01-25

Study on Stress Relief Analysis and Deformation of Thin-walled Structural Parts in Milling by Using Finite Element Method

Baimtec Material Co., Ltd., Beijing 100095, China

摘要

摘要: 薄壁件在航空航天领域应用广泛，其制造精度直接决定了装备的服役性能。然而，由于热处理的影响，导致薄壁件在加工之前存在残余应力。如果控制不当极易导致零件超差。因此，本文以7075铝合金板材为研究对象，分析了残余应力在板料淬火与预拉伸时产生的原理。进一步，采用有限元方法作为工具，对7075毛坯在淬火和预拉伸法过程中残余应力的产生进行了模拟。通过模拟发现，当毛坯件被拉伸约3%，塑性应变量约为2.4 %时，淬火残余应力消除可达91.2 %。在降低残余应力的基础上，本文建立了薄壁结构件铣削加工仿真模型，模拟了多因素耦合作用下的铣削加工变形，并通过铣削实验验证了仿真结果的正确性。
- 去应力 /
- 薄壁结构件 /
- 有限元模拟 /
- 残余应力 /
- 加工变形
Abstract: Thin-walled parts are widely used in aerospace applications, and their manufacturing accuracy directly determines the performance of the equipment in service. However, the effect of the heat treatment leads to the existence of residual stresses in thin-walled parts prior to machining. If not properly controlled, it is very easy to cause the part to exceed the tolerance. Therefore, for 7075 aluminum alloy sheet, the principle of residual stresses generated in the quenching and pre-stretching of the sheet is analyzed. Furthermore, the generation process of residual stresses in 7075 aluminum alloy blanks in the quenching process and pre-stretching is simulated by using the finite element method. It was found that the quenched residual stresses were reduced up to 91.2% when the blank was stretched by about 3% with a plastic strain of about 2.4%. According to the reduction of residual stresses, a simulation model for milling of thin-walled structural parts is established to simulate the milling deformation under the coupling effect of the multiple factors. The correctness of the simulation results is verified by using the milling experiments.
- stress relief /
- thin-walled structure part /
- finite element simulation /
- residual stress /
- machining distortion

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图 1 整体毛坯件尺寸

Figure 1. Monolithic blank dimension

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图 2 淬火后沿路径Z向的残余应力分布

Figure 2. Quenched residual stress distribution on path Z direction

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图 3 拉伸对淬火铝合金残余应力的影响

Figure 3. Effect of pre-stretching on quenched residual stress

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图 4 薄壁结构件尺寸

Figure 4. Thin-walled structural part dimension

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图 5 薄壁结构件有限元模型

Figure 5. FEM of thin-walled structural part

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图 6 不同铣刀状态下加载单元的受力模式

Figure 6. The forced pattern of load element under different milling states

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图 7 铣削加工模拟后的工件整体变形轮廓图

Figure 7. The contour distribution of part′s integral deformationafter milling process simulation

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图 8 铣削加工模拟后的工件整体变形分布图

Figure 8. The distribution of part′s integral deformation after milling process simulation

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图 9 薄壁结构件加工

Figure 9. Machining of thin-walled structural part

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图 10 加工后的工件

Figure 10. The machined part

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图 11 工件加工变形实验与有限元模拟对比图

Figure 11. Comparison of FEA simulation and workpiece machining distortion experiment

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表 1 7075铝合金的力学性能和热物理性能^[15]

Table 1. Mechanical and thermal properties of Al7075^[15]

温度/℃	20	100	200	300	400	500
弹性模量/GPa	71	65.19	56.26	37.98	31.5	25
塑性模量/MPa	250	210	150	50	15	10
屈服应力/MPa	455.9	389.1	275.7	47.1	35.5	16.3
热传导系数/[W·(m·℃)^-1]	115	120	140	150	160	170
比热/[J·(Kg·℃)^-1]	860	900	970	1020	1120	1320
对流换热系数/[W·(m²·℃)^-1]	2 660	5 000	12 880	10 000	3 000	350
平均热膨胀系数/(10^-6·℃^-1)	21.6	23.4	24.3	25.2	30.7	31.4
平均热膨胀系数/(10^-6·℃^-1)	(0~20 ℃)	(0~100 ℃)	(0~200 ℃)	(0~30 ℃)	(0~400 ℃)	(0~500 ℃)

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