Research on Machining Deformation Simulation and Deformation Control Technology Scheme of Guideway Beam Based on Residual Stress Redistribution
LIU Xueli1, WANG Yuhang2, LI Chaoran2, LI Caihong1, ZHANG Shengwei1, SUN Jianfei2, 3
1. AECC Aero Science and Technology Co., Ltd., Chengdu 610503, China;
2. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China;
3. Jingdezhen Branch of Jiangxi Research Institute, Beihang University, Jingdezhen 333000, China
摘要为解决大型薄壁铸件导轨梁在材料去除过程中因残余应力的释放与重分布导致变形超差的工艺难题,对导轨梁零件加工工艺进行分析,实现零件模型的简化与子结构分割;同时开展零件毛坯表面残余应力测量,成功建立零件毛坯初始应力模型。在此基础上结合实际加工工艺开展零件加工有限元仿真,模拟加工过程中由于材料去除引起的残余应力释放,预测了加工过程中残余应力重分布规律和加工变形情况。总结了零件加工变形的有限元仿真结果,提出抑制零件加工变形的工艺方案。经验证,改进后的工艺顺序使零件最大变形量由0.485 mm 降至0.081 mm,降低83.3%,避免了零件在加工过程中的尺寸超差。同时该平面作为后续加工的基准,保证了后续加工的精度,为生产工艺优化提供了有效的理论依据。
In order to solve the process problem of over-deformation caused by the release and redistribution of residual stress in the material removal process of large thin-walled casting guideway beam, the processing technology of guide beam parts was analyzed to realize the simplification of part model and substructure segmentation. At the same time, the surface residual stress measurement of the part blank was carried out, and the initial stress model of the part blank was successfully established. On this basis, the finite element simulation of part machining is carried out in combination with the actual machining process. The residual stress release caused by material removal during machining is simulated, and the residual stress redistribution law and machining deformation during machining are predicted. Summarize the finite element simulation results of the machining deformation of the parts, and propose a process plan to suppress the machining deformation of the parts. It is verified that the improved process sequence reduces the maximum deformation of the parts from 0.485 mm to 0.081 mm, which is reduced by 83.3%, and avoids the oversize of the parts during processing. At the same time, this plane is used as the benchmark for subsequent processing, which ensures the accuracy of subsequent processing and provides an effective theoretical basis for the optimization of production process.
刘雪丽,王宇航,李超然,李彩红,张晟玮,孙剑飞. 基于残余应力重分布的导轨梁加工变形仿真与变形控制工艺方案研究[J]. 航空制造技术, 2023, 66(13): 102-112.
LIU Xueli, WANG Yuhang, LI Chaoran, LI Caihong, ZHANG Shengwei, SUN Jianfei. Research on Machining Deformation Simulation and Deformation Control Technology Scheme of Guideway Beam Based on Residual Stress Redistribution[J]. Aeronautical Manufacturing Technology, 2023, 66(13): 102-112.