面向大型航空薄壁结构件高速加工的混联机床稳定性及工艺参数优化方法

As a vital basic equipment in aviation manufacturing industry, the five-axis hybrid machine is greatly demanded in the field of national economy and national defense safety. However, in the processing of aeronautical thin-walled structural components, the vibration often occurs and the finished surface quality is unreliable. Aiming at the key technical problems in the practical process of the five axis hybrid machine tool, which is designed for high-speed machining of aeronautical thin-walled structural components, the cutting stability and process parameters optimization method is studied in this project. The project intends to study the coupling milling modeling method of the hybrid machine’s tool- thin-walled component system, to study the coupling mechanism between the tool and the thin-walled component. On the base of stability analysis, an adaptive process parameter optimization method, which aims at the maximum material removal rate and vibration attenuation, is proposed. The research is applied to a five-axis hybrid machine tool, to improve and verify related theories above and realize high-speed and high-quality machining of thin-walled components. The research above will provide scientific and technical basis for the solving the key technology problems of the hybrid machine tool in application of milling thin-walled components, promote the practicability of the five-axis hybrid machines, and enhance China's independent research and development ability and the overall level in the field of aerospace industry equipment.

五轴混联机床作为航空制造业中至关重要的基础设备，在国民经济和国防安全中有着巨大需求，然而在航空薄壁件加工中存在加工质量难保证、易发生振动等问题。项目针对面向航空薄壁件加工的五轴混联机床实用化过程中的关键技术难题，开展铣削稳定性及工艺参数优化方法研究。项目拟研究混联机床的变参数弹性动力学建模方法，研究混联机床-航空薄壁件铣削动力学建模及耦合机理；基于稳定域分析，提出一种以最大材料去除率和振动衰减度为目标的自适应工艺参数优化方法；将上述研究应用到一台五轴混联机床中，验证并完善相关理论研究，并实现典型航空薄壁件的高速高质量加工。以上研究力争为解决面向航空薄壁件加工的混联机床应用中的关键技术问题提供科学依据和技术基础，推动五轴混联加工装备的实用化进程，提升我国航空工业装备自主研发能力和整体水平。

五轴混联加工装备作为航空制造业中至关重要的基础设备，是传统产业转型升级和战略新兴产业发展的国之重器，然而在实际加工薄壁件过程中存在着加工效率低、易激发颤振的问题。项目针对面向航空薄壁件加工的五轴混联机床实用化过程中的关键技术难题，开展了薄壁件铣削稳定性和工艺参数优化研究。基于有限元和结构矩阵法，考虑不同位姿下铰链变刚度特性和复杂部件变截面特性，对混联机床进行弹性动力学建模。建立了薄壁件铣削过程中柔性变形模型和变形误差补偿模型，揭示了变形沿刀具路径的变化规律；基于自由界面法和动力学修正技术，提出了铣削过程薄壁件时变动力学参数更新方法。建立了刀具-薄壁件铣削动力学模型，研究了机床位姿、工件变形和材料去除效应对稳定域的影响。基于稳定域分析，采用遗传算法和神经网络提出了适用于混联机床加工薄壁件的智能工艺参数优化方法。在此基础上，将稳定性分析和工艺参数优化方法应用于一台混联机床样机，成功完成了两种典型航空薄壁件的加工，提高了五轴混联机床的高效、高质量加工能力。本项目为解决面向航空薄壁件加工的混联机床应用中的瓶颈技术问题提供了理论指导和技术支持，对推动五轴混联加工装备实用化进程、提升我国航空工业装备自主研发能力具有重要意义。