航空齿轮薄辐板车削加工变形预测及切削参数优化研究

宦海祥; 王孟雄; 张可

doi:10.13433/j.cnki.1003-8728.20230389

航空齿轮薄辐板车削加工变形预测及切削参数优化研究

doi: 10.13433/j.cnki.1003-8728.20230389

盐城工学院机械工程学院, 江苏盐城 224051

基金项目:

国家级重点实验室开放课题 4HTL-O-20G04

详细信息

作者简介:
宦海祥, 副教授, 硕士生导师, 博士, hhxjs@126.com

中图分类号: TG506.6
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- 文章访问数: 84
- HTML全文浏览量: 39
- PDF下载量: 14
- 被引次数: 0
出版历程
- 收稿日期: 2023-09-27
- 刊出日期: 2024-01-25

Study on Deformation Prediction and Cutting Parameters Optimization for Turning of Thin-walled Gear Spoke in Aerospace

School of Mechanical Engineering, Yancheng Institute of Technology, Yancheng 224051, Jiangsu, China

摘要

摘要: 为了满足直升机传动系统轻量化的需求，作为直升机关键零部件的传动齿轮具有薄壁的显著特征，在切削加工中容易出现变形严重和尺寸精度难以保证的问题。本文以高强度中合金渗碳钢齿轮薄辐板为研究对象，基于ABAQUS有限元分析软件，开展了切削加工仿真研究，通过建立三维动态切削仿真模型，分析了加工过程中工件所受的切削力与切削参数之间的关系；并运用静态仿真分析了切削力和夹紧力叠加对薄辐板加工变形的影响，对仿真结果进行了极差分析。最后，通过开展试验对仿真结果进行了验证。结果表明: 齿轮薄辐板加工变形量静力学分析显示齿轮辐板轴向变形量最大，径向变形在轮毂处最大；极差分析发现，切削速度为150 m/min、进给量为0.06 mm/r、切削深度为1.8 mm为最优切削参数，最大变形量的预测误差小于10%。
- 齿轮薄辐板 /
- 切削仿真 /
- 变形预测 /
- 参数优化 /
- 切削力
Abstract: To fulfill the lightweight requirements of helicopter transmission systems, transmission gears as a critical component of helicopters, possess the noticeable characteristic of thin walls, which presents challenges in terms of severe deformation and the assurance of dimensional precision during the machining process. This article focuses on the study of thin-walled gear spoke plate made from high-strength medium alloy carburized steel. Using the ABAQUS finite element analysis software, a simulation study on the cutting process was conducted. By establishing a three-dimensional dynamic cutting simulation model, the relationship between the cutting forces and the cutting parameters on the parts in the machining was analyzed. Static simulation methods were used to analyze the influence of the superposition of cutting force and clamping force on the processing deformation of thin-walled spoke. Then range analysis was used to examine the simulation results. Finally, the experimental validation of the simulation results was carried out. The results indicate that in the static analysis of gear thin-walled spoke plate machining deformation, the axial deformation of the gear spoke plate is most significant, and the radial deformation is most prominent at the hub. Range analysis reveals that the optimal cutting parameters are the cutting speed of 150 m/min, the feed rate of 0.06 mm/r, and the cutting depth of 1.8 mm, with the prediction error for the maximum deformation of below 10%.
- gear thin spoke plates /
- cutting simulation /
- deformation prediction /
- parameter optimization /
- cutting force

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图 1 齿轮薄辐板加工简图

Figure 1. Gear thin spoke plate machining

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图 2 端面切槽刀杆参数

Figure 2. Parameters of end grooving toolholder

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图 3 轴向进给加工方式原理图

Figure 3. Schematic diagram of axial feed machining method

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图 4 三维仿真模型网格划分示意图

Figure 4. Schematic diagram of meshing of the 3D simulation model

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图 5 切削过程应力云图

Figure 5. Stress cloud map of cutting process

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图 6 切削力变化曲线

Figure 6. Cutting force variation curve

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图 7 车削加工过程中辐板位移云图

Figure 7. Spoke displacement cloud map during turning process

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图 8 加工流程及测量方式

Figure 8. Machining procedures and measurement method

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图 9 变形量U与切削参数之间的响应关系

Figure 9. Response relationship between deformation U and cutting parameters

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图 10 三坐标测量仪测量图U

Figure 10. Coordinate Measuring Machine Measurement Diagram U

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表 1 18Cr2Ni4WA的物理、力学、热学参数^[20]

Table 1. Physical, mechanical and thermal parameters of 18Cr2Ni4WA^[20]

参数	数值
密度/(kg·m^-3)	7 910
杨氏模量/GPa	202
泊松比	0.27
熔点/℃	1 800
热传导率/(W·℃^-1)	44
热膨胀系数/℃^-1	1.24×10^-5
比热/[J·(kg·℃)^-1]	460
非弹性热系数	0.9

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表 2 切削仿真L₁₆(4³)正交实验表

Table 2. Table of orthogonal experiments for cutting simulation L₁₆(4³)

水平	切削速度v_c/(m·min^-1)	进给量f/(mm·r^-1)	切削深度w/mm
1	90	0.06	1.8
2	110	0.08	2.0
3	130	0.10	2.2
4	150	0.12	2.4

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表 3 切削力与变形量仿真实验结果

Table 3. Cutting force and deformation simulation results

试验	切削速度水平	进给量水平	切削深度水平	F_c/N	F_f/N	U/mm
1	1	1	1	315.29	283.94	0.084
2	1	2	2	471.39	356.58	0.125
3	1	3	3	578.32	391.46	0.171
4	1	4	4	660.81	428.38	0.241
5	2	1	2	390.06	348.56	0.102
6	2	2	1	402.92	398.23	0.099
7	2	3	4	603.81	460.19	0.206
8	2	4	3	616.08	465.99	0.202
9	3	1	3	409.66	221.33	0.122
10	3	2	4	515.51	297.93	0.171
11	3	3	1	469.12	288.63	0.112
12	3	4	2	576.49	321.33	0.160
13	4	1	4	439.99	298.54	0.137
14	4	2	3	466.80	344.14	0.144
15	4	3	2	518.64	361.74	0.137
16	4	4	1	508.78	373.14	0.130

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表 4 辐板变形量U极差分析表

Table 4. U-pole analysis of spoke plate deformations

参数	切削速度v_c/(m·min^-1)	进给量f/(mm·r^-1)	切削深度w/mm
K₁	0.621	0.445	0.425
K₂	0.609	0.539	0.524
K₃	0.565	0.626	0.639
K₄	0.548	0.733	0.755
k₁	0.155 3	0.111 3	0.106 3
k₂	0.152 3	0.134 8	0.131 0
k₃	0.141 3	0.156 5	0.159 8
k₄	0.137 0	0.183 4	0.188 8
R	0.018 3	0.072 1	0.082 5

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