TC4钛合金材料铣削加工分析及参数优化

doi:10.13229/j.cnki.jdxbgxb.20220681

Abstract

Abstract:

In order to investigate the influence of milling parameters on the milling force and material removal rate when machining TC4 titanium alloy material and to find the best combination of parameters， side milling experiments designed based on the orthogonal experimental method were carried out with a four-edged ball-ended milling cutter. Milling speed， feed per tooth， milling depth and milling width were chosen as variables， while milling force and material removal rate were selected as evaluation indicators. The influence laws of machining parameters on milling force and material removal rate， based on the range analysis method， were found out. The grey relational analysis （GRA） and particle swarm optimization （PSO） algorithms were adopted to optimize the milling parameters respectively， meanwhile a milling force prediction model was established based on the regression analysis method to prepare for the PSO. Finally， the two optimization methods were compared and analyzed and the prediction model was verified through the verification experiments. The results show that the prediction model established in this paper can accurately and efficiently predict the milling force， and the optimization effect of PSO is much better.

Key words: mechanical manufacture, titanium alloy, milling force, material removal rate, grey relational analysis, particle swarm optimization

CLC Number:

TH161

Ya-dong GONG,Ming-xiang DING,Xiang LI,Jin-min TIAN. Milling analysis and parameter optimization for TC4 titanium alloy material[J].Journal of Jilin University(Engineering and Technology Edition), 2024, 54(4): 917-925.

Figures/Tables 18

Table 1

Fig.1

Table 2

Levels of experimental factors"

水平	铣削速度 $v c / m · m i n - 1$	每齿进给量 $f z / m m · z - 1$	铣削深度 $a p / m m$	铣削宽度 $a e / m m$
1	60	0.01	2.5	0.25
2	80	0.02	5	0.50
3	100	0.03	7.5	0.75
4	120	0.04	10	1.00

Table 2

Table 3

Experimental results of orthogonalexperimental design"

实验编号	$v c$ / （m·min^-1）	$f z$ / （mm·z^-1）	$a p$ /mm	$a e$ /mm	F/N	MRR/（mm³·min^-1）
1	60	0.01	2.5	0.25	22.625	79.58
2	60	0.02	5	0.5	66.936	636.62
3	60	0.03	7.5	0.75	131.299	2148.59
4	60	0.04	10	1	196.573	5092.96
5	80	0.01	5	0.75	61.519	636.62
6	80	0.02	2.5	1	59.103	848.82
7	80	0.03	10	0.25	115.367	1273.24
8	80	0.04	7.5	0.5	120.821	2546.48
9	100	0.01	7.5	1	79.705	1591.55
10	100	0.02	10	0.75	121.917	3183.10
11	100	0.03	2.5	0.5	79.483	795.77
12	100	0.04	5	0.25	68.193	1061.03
13	120	0.01	10	0.5	70.012	1273.24
14	120	0.02	7.5	0.25	69.557	954.93
15	120	0.03	5	1	98.043	3819.72
16	120	0.04	2.5	0.75	82.287	1909.86

Table 3

Table 4

Range analysis results of resultant force F"

水平	$v c$	$f z$	$a p$	$a e$
1	104.36	58.47	60.87	68.94
2	89.20	79.38	73.67	84.31
3	87.32	106.05	100.35	99.26
4	79.97	116.97	125.97	108.36
Delta	24.38	58.50	65.09	39.42
排秩	4	2	1	3

Table 4

Fig.2

Table 5

Range analysis results of material removal rate"

水平	$v c$	$f z$	$a p$	$a e$
1	1989.4	895.2	908.5	842.2
2	1326.3	1405.9	1538.5	1313.0
3	1657.9	2009.3	1810.4	1969.5
4	1989.4	2652.6	2705.6	2838.3
Delta	663.1	1757.3	1797.1	1996.1
排秩	4	3	2	1

Table 5

Fig.3

Fig.4

Table 6

Table 7

Mean values of GRC"

项目	F				MRR
项目	$v c$	$f z$	$a p$	$a e$	$v c$	$f z$	$a p$	$a e$
水平1	0.6406	0.4679	0.4762	0.5046	0.635	0.5187	0.5196	0.5143
水平2	0.5787	0.5445	0.5241	0.5615	0.5968	0.6017	0.6121	0.5946
水平3	0.5720	0.6376	0.6181	0.6144	0.638 8	0.6784	0.6630	0.6755
水平4	0.5459	0.6871	0.7187	0.6567	0.6780	0.7499	0.7539	0.7642
$R i j$	0.0947	0.2192	0.2425	0.1522	0.0812	0.2312	0.2343	0.2499
$∑ R i j$	0.7086				0.7966
$w k$	0.47				0.53

Table 7

Table 8

Table 9

Measurement of weighted grey relevance by range method"

铣削参数	代号	均值加权灰色关联度				$Δ$	排序
铣削参数	代号	水平1	水平2	水平3	水平4	$Δ$	排序
$v c$	A	0.6376*	0.5883	0.6074	0.6159	0.0493	4
$f z$	B	0.4948	0.5748	0.6592	0.7204*	0.2256	2
$a p$	C	0.4992	0.5708	0.6419	0.7374*	0.2382	1
$a e$	D	0.5097	0.5790	0.6468	0.7137*	0.2040	3

Table 9

Fig.5

Fig.6

Table 10

Fig.7

Fig.8

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实验编号	信噪比（S/N）		归一化		GRC
实验编号	F	MRR	F	MRR	F	MRR
1	-27.091 77	38.016 08	0	0	0.333 33	0.333 33
2	-36.513 20	56.077 61	0.501 71	0.500 00	0.500 86	0.500 00
3	-42.365 23	66.643 07	0.813 34	0.792 48	0.728 16	0.706 69
4	-45.870 48	74.139 41	1	1	1.000 00	1.000 00
5	-35.780 19	56.077 61	0.462 67	0.500 00	0.482 01	0.500 00
6	-35.432 19	58.576 31	0.444 14	0.569 17	0.473 55	0.537 15
7	-41.241 63	62.098 21	0.753 51	0.666 66	0.669 80	0.600 00
8	-41.642 85	68.118 81	0.774 87	0.833 33	0.689 53	0.750 00
9	-38.029 71	64.036 41	0.582 47	0.720 32	0.544 94	0.641 29
10	-41.721 29	70.057 01	0.779 05	0.886 99	0.693 53	0.815 64
11	-38.005 49	58.015 75	0.581 17	0.553 65	0.544 17	0.528 35
12	-36.674 80	60.514 55	0.510 31	0.622 82	0.505 21	0.570 01
13	-36.903 45	62.098 21	0.522 49	0.666 66	0.511 50	0.600 00
14	-36.846 82	59.599 43	0.519 47	0.597 49	0.509 93	0.554 01
15	-39.828 33	71.640 63	0.678 24	0.930 83	0.608 45	0.878 47
16	-38.306 62	65.620 03	0.597 21	0.764 16	0.553 84	0.679 49

实验编号	WGRG	排序
1	0.333 33	16
2	0.500 40	14
3	0.716 78	5
4	1.000 00	1
5	0.491 54	15
6	0.507 26	13
7	0.632 80	6
8	0.721 58	4
9	0.596 00	8
10	0.758 25	2
11	0.535 78	11
12	0.539 55	10
13	0.558 41	9
14	0.533 29	12
15	0.751 56	3
16	0.620 44	7

项目	平方和	自由度	均方	F	显著性
总计	24 145.673	15
回归	24 124.905	13	1 855.762	178.721	0.006
残差	20.767	2	10.384

Milling analysis and parameter optimization for TC4 titanium alloy material

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