Corner milling force prediction and improvement method of aviation thin-walled structural parts

Abstract

Corner is one of the typical characteristics of aerospace monolithic components. In order to achieve a stable processing environment and reduce the mutation of milling force in the process of machining, the manufacturer has been searching a method to control the milling force of corner machining. Based on the cutting contact relationship and the instantaneous chip thickness, the milling force prediction model of corner machining is established. By analyzing different types of corner contact relationship, the influence of cutting contact angle and cutting arc length on milling force is established. The corner feed rate iterative calculation method is used to improve the corner milling force mutation. The corner milling experiment proves that the proposed method can not only effectively control the corner milling force, but also improve the surface quality of the bottom surface of the workpiece. The proposed method is suitable for automatic programming of multi-corner pocket machining and provides theoretical support for stable machining of frame part.

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

“…Milling of thin-walled workpieces, such as multi-framed structure workpiece, complex geometric feature workpiece et al is a common manufacturing process and widely used in aviation and weapon industry [1][2][3][4]. In milling of these aluminum alloy thin-walled workpiece, a large number of burrs obviously generates on the entrances and exits of cutting tool on workpiece surface, which affects machining quality, assembly accuracy and produces more seriously tip discharge effect caused the failure of weapon guidance and other precise systems [5][6][7].…”