Machining deformation control methods and analysis of a thin-walled gear spoke plate

• Published in: International journal of advanced manufacturing technology Vol. 127; no. 3-4; pp. 1317 - 1331
• Main Authors: Huan, Haixiang, Zhang, Ke, Xu, Jiuhua, Xu, Wenqiang, Wang, Mengxiong
• Format: Journal Article
• Language: English
• Published: London Springer London 01.07.2023; Springer Nature B.V
• Subjects: Accuracy; CAE) and Design; Clamping; Computer simulation; Computer-Aided Engineering (CAD; Control methods; Coordinate measuring machines; Cutting force; Cutting parameters; Deformation effects; Design optimization; Engineering; Finite element method; Gear machining; Helicopters; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Media Management; Metal cutting; Original Article; Residual stress; Simulation; Software; Turning (machining); Two dimensional models; Workpieces; Deformation analysis and simulation; Clamping method; Cutting simulation; Thin-walled gear
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-11609-5

This paper addresses the problems of easy deformation, difficult dimensional control and difficult accuracy assurance during the production of thin-walled gears for helicopter spoke cutting. It uses finite element simulation technology, metal cutting principles, process optimization and other design and manufacturing technologies to reveal the causes of cutting deformation, effectively predict the deformation of parts during cutting, and develop reasonable deformation control strategies. This study explores the effects of cutting force, residual stress and clamping method on gear machining deformation. The deformation of the spoke plate is analysed by finite element simulation. Abaqus software is adopted to establish a finite element model for 2D turning simulation to predict the machining residual stresses and cutting forces during gear turning machining with different cutting parameters. The simulated cutting forces are compared with the residual stresses and experimentally measured values to verify the accuracy of the finite element model and provide a theoretical basis for model construction in the next simulation study. With Abaqus software, the effect of different cutting forces on the deformation of the spoke plate is simulated, and the effect of the superposition of cutting and clamping forces on the deformation of the spoke plate is simulated using life and death cell technology to simulate the machining of the workpiece. Then, a corresponding fixture is designed to realise the corresponding clamping position for machining experiments, and the deformation of the spoke plate is measured by CMM (coordinate measuring machine) to verify the realism of the simulation. This research provides scientific theoretical guidance and process support for aerospace thin-walled gear spoke plate turning.