{"title":"多载荷序列耦合条件下空心薄壁铝合金结构件的变形预测模型","authors":"Jiaheng Ma, Shengfang Zhang, Fujian Ma, Xiuying Song, Ziguang Wang, Zhihua Sha","doi":"10.1007/s10845-024-02464-6","DOIUrl":null,"url":null,"abstract":"<p>Hollow thin-walled aluminum alloy structural parts (HTWASP) must be cut after welding during the actual processing process, and a welding stress field is inevitably generated owing to the welding heat effect in the process of welding the workpiece, leading to distortion of workpiece. To accurately and efficiently predict the deformation of HTWASP after multiprocess processing, equivalent load caused by process of welding was computed through connection inherent strain theory with welding thermal parameters. A dynamic simulation model of the milling process of HTWASP was established by welding equivalent load. The influences of spindle speed and tool diameter on the deformation remain stress of structural workpieces were analyzed. Additionally, the simulated values for the deformation of the workpiece were compared and analyzed through milling tests on these structural parts. The results showed that the range of stress values and stress effects was smaller when the spindle speed was higher. The distance of the stress effect was the smallest when machine speed was 2500 rpm and tool diameter was 20 mm. Milling stress value was the smallest when machine speed was 2500 rpm and tool diameter was 6 mm. Most of the deformation occurred in the hollow position of the upper and diagonal plate; in contrast, the distortion of vertical plate and weld seam was not significant. The minimum deformation was 0.501 mm at machine speed is 2500 rpm and tool diameter is 6 mm. In the non-high-speed cutting state, high speed reduced workpiece quality of aluminum alloy workpiece, and slot milling quality was the best when machine speed was 1000 r/min and tool diameter was 6 mm. The proposed model sequentially couples the welding and milling process loads, and a multiprocess deformation prediction model that increasingly conforms to the actual processing sequence is constructed, providing a reference for the high-precision and efficient prediction of the multiprocess deformation in hollow thin-walled structural parts.</p>","PeriodicalId":16193,"journal":{"name":"Journal of Intelligent Manufacturing","volume":"67 1","pages":""},"PeriodicalIF":5.9000,"publicationDate":"2024-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Deformation prediction model for hollow thin-walled aluminum alloy structural parts under multiple load-sequence coupling conditions\",\"authors\":\"Jiaheng Ma, Shengfang Zhang, Fujian Ma, Xiuying Song, Ziguang Wang, Zhihua Sha\",\"doi\":\"10.1007/s10845-024-02464-6\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"<p>Hollow thin-walled aluminum alloy structural parts (HTWASP) must be cut after welding during the actual processing process, and a welding stress field is inevitably generated owing to the welding heat effect in the process of welding the workpiece, leading to distortion of workpiece. To accurately and efficiently predict the deformation of HTWASP after multiprocess processing, equivalent load caused by process of welding was computed through connection inherent strain theory with welding thermal parameters. A dynamic simulation model of the milling process of HTWASP was established by welding equivalent load. The influences of spindle speed and tool diameter on the deformation remain stress of structural workpieces were analyzed. Additionally, the simulated values for the deformation of the workpiece were compared and analyzed through milling tests on these structural parts. The results showed that the range of stress values and stress effects was smaller when the spindle speed was higher. The distance of the stress effect was the smallest when machine speed was 2500 rpm and tool diameter was 20 mm. Milling stress value was the smallest when machine speed was 2500 rpm and tool diameter was 6 mm. Most of the deformation occurred in the hollow position of the upper and diagonal plate; in contrast, the distortion of vertical plate and weld seam was not significant. The minimum deformation was 0.501 mm at machine speed is 2500 rpm and tool diameter is 6 mm. In the non-high-speed cutting state, high speed reduced workpiece quality of aluminum alloy workpiece, and slot milling quality was the best when machine speed was 1000 r/min and tool diameter was 6 mm. The proposed model sequentially couples the welding and milling process loads, and a multiprocess deformation prediction model that increasingly conforms to the actual processing sequence is constructed, providing a reference for the high-precision and efficient prediction of the multiprocess deformation in hollow thin-walled structural parts.</p>\",\"PeriodicalId\":16193,\"journal\":{\"name\":\"Journal of Intelligent Manufacturing\",\"volume\":\"67 1\",\"pages\":\"\"},\"PeriodicalIF\":5.9000,\"publicationDate\":\"2024-07-26\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Journal of Intelligent Manufacturing\",\"FirstCategoryId\":\"5\",\"ListUrlMain\":\"https://doi.org/10.1007/s10845-024-02464-6\",\"RegionNum\":2,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q1\",\"JCRName\":\"COMPUTER SCIENCE, ARTIFICIAL INTELLIGENCE\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Intelligent Manufacturing","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1007/s10845-024-02464-6","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"COMPUTER SCIENCE, ARTIFICIAL INTELLIGENCE","Score":null,"Total":0}
引用次数: 0
摘要
中空薄壁铝合金结构件(HTWASP)在实际加工过程中必须经过焊接切割,工件在焊接过程中由于焊接热效应不可避免地会产生焊接应力场,导致工件变形。为了准确有效地预测 HTWASP 在多工序加工后的变形,通过将固有应变理论与焊接热参数联系起来,计算了焊接过程引起的等效载荷。通过焊接等效载荷建立了 HTWASP 铣削过程的动态仿真模型。分析了主轴转速和刀具直径对结构工件变形应力的影响。此外,通过对这些结构件的铣削试验,对工件变形的模拟值进行了比较和分析。结果表明,主轴转速越高,应力值和应力效应的范围越小。当机床转速为 2500 rpm,刀具直径为 20 mm 时,应力效应的距离最小。当机床转速为 2500 rpm,刀具直径为 6 mm 时,铣削应力值最小。大部分变形发生在上板和斜板的中空位置;相比之下,竖板和焊缝的变形并不明显。在机床转速为 2500 rpm、刀具直径为 6 mm 时,最小变形量为 0.501 mm。在非高速切削状态下,高速降低了铝合金工件的质量,而当机床转速为 1000 r/min、刀具直径为 6 mm 时,槽铣质量最好。提出的模型将焊接和铣削工序载荷顺序耦合,构建了越来越符合实际加工顺序的多工序变形预测模型,为高精度、高效率地预测空心薄壁结构件的多工序变形提供了参考。
Deformation prediction model for hollow thin-walled aluminum alloy structural parts under multiple load-sequence coupling conditions
Hollow thin-walled aluminum alloy structural parts (HTWASP) must be cut after welding during the actual processing process, and a welding stress field is inevitably generated owing to the welding heat effect in the process of welding the workpiece, leading to distortion of workpiece. To accurately and efficiently predict the deformation of HTWASP after multiprocess processing, equivalent load caused by process of welding was computed through connection inherent strain theory with welding thermal parameters. A dynamic simulation model of the milling process of HTWASP was established by welding equivalent load. The influences of spindle speed and tool diameter on the deformation remain stress of structural workpieces were analyzed. Additionally, the simulated values for the deformation of the workpiece were compared and analyzed through milling tests on these structural parts. The results showed that the range of stress values and stress effects was smaller when the spindle speed was higher. The distance of the stress effect was the smallest when machine speed was 2500 rpm and tool diameter was 20 mm. Milling stress value was the smallest when machine speed was 2500 rpm and tool diameter was 6 mm. Most of the deformation occurred in the hollow position of the upper and diagonal plate; in contrast, the distortion of vertical plate and weld seam was not significant. The minimum deformation was 0.501 mm at machine speed is 2500 rpm and tool diameter is 6 mm. In the non-high-speed cutting state, high speed reduced workpiece quality of aluminum alloy workpiece, and slot milling quality was the best when machine speed was 1000 r/min and tool diameter was 6 mm. The proposed model sequentially couples the welding and milling process loads, and a multiprocess deformation prediction model that increasingly conforms to the actual processing sequence is constructed, providing a reference for the high-precision and efficient prediction of the multiprocess deformation in hollow thin-walled structural parts.
期刊介绍:
The Journal of Nonlinear Engineering aims to be a platform for sharing original research results in theoretical, experimental, practical, and applied nonlinear phenomena within engineering. It serves as a forum to exchange ideas and applications of nonlinear problems across various engineering disciplines. Articles are considered for publication if they explore nonlinearities in engineering systems, offering realistic mathematical modeling, utilizing nonlinearity for new designs, stabilizing systems, understanding system behavior through nonlinearity, optimizing systems based on nonlinear interactions, and developing algorithms to harness and leverage nonlinear elements.