基于曲面响应法分析6061铝合金铣削参数对表面粗糙度的影响

发布时间：2018-05-19 23:10

本文选题：Deform-3D + 正交回归分析法　；参考：《兰州理工大学》2017年硕士论文

【摘要】：在汽车制造业突飞猛进的今天,汽车零部件的生产能力直接影响汽车产业的发展,缸盖、缸体是发动机最重要、最核心的零件,因此,发动机缸体、缸盖的制造水平对一个国家汽车制造业的水平有着至关重要的作用。在全世界节能减排的大背景下,汽车燃油经济性越来越受到汽车制造商的关注,而全铝发动机的应用更好地促进了汽车节能减排的实现。6061铝合金以其高抗拉强度、抗腐蚀性和耐疲劳等机械性能成为理想的结构材料,被广泛应用于汽车零件、飞机机身材料及航空工业等方面。汽车发动机缸体多数采用铝合金材料以减轻自重。由于发动机缸体为密封件,对缸盖等表面加工质量要求较高,并且判断切削加工零件表面质量的重要指标之一是表面粗糙度,所以在实际生产过程中,为使零件的加工质量能够达到工艺要求,需要对表面粗糙度进行预测,通过预测结果对试验进行指导。在生产加工过程中,切削参数对加工零件表面粗糙度的影响以及加工效率的提升极为重要,因此筛选合理的切削加工工艺参数有利于提高加工表面质量和加工效率。本文对6061铝合金进行高速铣削仿真试验、指导实际加工,并对分析方法进行对比,对试验结果展开研究,文章主要研究内容以及成果为:(1)利用Matlab和Design-Expert软件设计正交回归试验方案和二次曲面响应试验方案,应用Deform-3D软件建立工件、刀具模型,并对高速铣削6061铝合金进行仿真分析,观察表面质量及测量、筛选、计算表面粗糙度数值。(2)分别用正交回归分析法和二次曲面响应法两种分析方法对表面粗糙度与切削参数关系模型进行拟合,得到表面粗糙度与切削参数间的数值关系,并对两进个模型分别进行残差分析,以及利用方差分析与显著性检验对比两种分析方法的差异与优劣,结果得出:相比于正交回归分析法,曲面响应法拟合效果更好,具有较高的置信度和实用性,适用于表面粗糙度的预测、优化和控制。(3)利用曲面响应法分析切削参数对表面粗糙度的影响,并结合材料去除率,在控制加工表面质量和加工效率的前提下,得出切削参数影响表面粗糙度的主次顺序以及最优组合,最终利用切削加工试验验证上述仿真分析正确性。
[Abstract]:Today, with the rapid development of the automobile manufacturing industry, the production capacity of automobile parts directly affects the development of the automobile industry. Cylinder head and cylinder block are the most important and core parts of the engine. Therefore, the engine cylinder block, Cylinder head manufacturing level plays an important role in a country's automobile manufacturing level. Under the background of energy saving and emission reduction in the world, automobile fuel economy has been paid more and more attention by automobile manufacturers, and the application of all-aluminum engine has better promoted the realization of energy saving and emission reduction of automobile. 6061 aluminum alloy has its high tensile strength. Mechanical properties such as corrosion resistance and fatigue resistance have become ideal structural materials, which are widely used in automotive parts, aircraft fuselage materials and aviation industry. The automobile engine cylinder block mostly uses the aluminum alloy material to reduce the self-weight. Because the engine cylinder block is a sealing part, the machining quality of cylinder head and other surfaces is very high, and one of the important indexes to judge the surface quality of machined parts is the surface roughness, so in the actual production process, In order to make the machining quality of the parts meet the technological requirements, it is necessary to predict the surface roughness and guide the test through the prediction results. In the process of production and processing, the influence of cutting parameters on the surface roughness of machined parts and the improvement of machining efficiency are very important. Therefore, the selection of reasonable cutting process parameters is helpful to improve the quality of machined surface and the efficiency of machining. In this paper, the high speed milling simulation test of 6061 aluminum alloy is carried out to guide the actual machining, and the analysis method is compared, and the experimental results are studied. The main contents and results of this paper are as follows: (1) the orthogonal regression test scheme and Quadric surface response test scheme are designed by using Matlab and Design-Expert software. The workpiece and tool models are established by using Deform-3D software, and the simulation analysis of high speed milling of 6061 aluminum alloy is carried out. Observing the surface quality and measuring, screening, calculating the surface roughness value.) fitting the model of the relationship between the surface roughness and the cutting parameters by the orthogonal regression analysis method and the Quadric surface response method, respectively. The numerical relationship between surface roughness and cutting parameters is obtained, and the residual analysis of the two models is carried out, and the differences and advantages of the two analysis methods are compared by means of variance analysis and significance test. The results show that compared with the orthogonal regression method, the surface response method has better fitting effect, higher confidence and practicability, and is suitable for the prediction of surface roughness. The surface response method is used to analyze the influence of cutting parameters on the surface roughness, and the material removal rate is used to control the surface quality and efficiency. The cutting parameters affect the primary and secondary order and the optimal combination of surface roughness. Finally, the correctness of the simulation analysis is verified by cutting experiments.
【学位授予单位】：兰州理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG54

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