Machining deformation of gear blank integral components

Based on theoretical calculation and finite element simulation, Sun Jie and Ke Yinglin of Zhejiang University studied the influence of the initial internal stress of the gear blank of large integral structure on its NC machining deformation, and solved the deformation of the rectangular section beam with unidirectional stress in the component during layer by layer machining. Wu Hongbing of Zhejiang University studied and arranged experiments to verify the machining deformation principle of thin-walled parts from the aspects of cutting principle and finite element simulation technology, using the methods of mathematical model calculation and finite element simulation. Lu Dong of Shandong University comprehensively considered the influence of the initial internal stress of the gear blank, the milling stress, the temperature change of the gear blank during machining and the clamping stress on the deformation of the frame integral structure, and established the deformation prediction model of the aviation integral structure under the coupling of various complex relationships by combining theoretical analysis with practical machining. By simulating the application of gear blank stress and the processing process of structural parts, the deformation characteristics and stress changes of frame structural parts can be predicted, which lays a theoretical foundation for the processing deformation control and process optimization of the whole structural parts.

Aiming at the deformation behavior of aviation frame integral structure parts in milling, Qunlin and Ke Yinglin of Zhejiang University physically simulated the whole milling process of aviation frame integral structure parts based on the calculation principle of relay, and established a calculation system based on relay. Through experimental verification and comparison, it is known that the numerical simulation method based on relay calculation can effectively predict the machining deformation of aviation integral structural parts. Zhou Wenchao of Nanjing University of Aeronautics and Astronautics established a finite element model to predict the deformation of annular thin-walled parts during machining, analyzed the influence of cutting stress on the machining accuracy of annular thin-walled parts, measured the internal stress of gear blank materials at high temperature, and predicted the relationship between the removal of gear blank materials and the machining error of annular thin-walled parts by using finite element simulation analysis technology according to the obtained stress data. Huang Xiaoming of Shandong University used the theoretical calculation method to analyze the stiffness change, internal stress distribution and deformation of the gear blank in the process of machining, combined the finite element simulation with the actual machining, and established the machining deformation prediction model of the integral structure through the deformation prediction of the integral component under the influence of single factor and multi factor comprehensive influence, It provides a theoretical basis for the deformation control of aviation structural parts.

Nervi s of the United States established the deformation prediction model in the machining process of gear blank containing initial internal stress, and analyzed the relationship between the distribution state of initial internal stress of gear blank and the deformation degree of parts. Keith studied the influence of machining stress on the machining deformation of components. The research results show that the machining stress is closely related to the arc radius of milling cutter tip and cutting edge, while the machining stress has a greater influence on the machining deformation of thin-walled structural parts. Ratchev et al established a mathematical model for predicting the machining deformation of thin-walled parts based on neural network, carried out finite element analysis on the gear blank of thin-walled parts, and predicted the machining error of parts.

To sum up, by adopting relevant theoretical analysis and deformation control methods, the overall component processing deformation prediction and control in aviation and other fields can be effectively realized. Therefore, combined with the deformation control theory of integral component processing, according to the structural characteristics and material removal mode of split spur bevel gear, a systematic and in-depth study on its deformation mechanism and control strategy is an effective way to realize the prediction and control of cutting deformation of split spur bevel gear.

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