复杂约束下镜像铣削支撑-薄壁件系统动力学特性预测

Dynamic characteristic prediction of a thin-walled workpiece-support system in mirror milling under complex fixturing constraints

  • 摘要: 针对薄壁件镜像铣削系统因夹具约束和支撑作用等复杂边界条件导致动力学模型难以精确建立的问题,提出了一种基于4节点四边形有限薄膜应变线性减缩积分壳单元S4R和遗传算法的动力学精确建模方法,适用于复杂夹具约束下薄壁件镜像铣削支撑-工件系统的动力学特性预测。基于S4R壳单元与8节点六面体线性减缩积分单元C3D8R的网格收敛性结果对比,确定采用S4R壳单元构建系统初始动力学模型,并将夹具与支撑装置等效为弹簧单元以施加边界条件。以支撑-工件系统实测频率响应函数与仿真频响间的误差为目标函数,利用遗传算法对等效弹簧刚度、模态阻尼比等关键参数进行寻优辨识,结果表明优化后的模型计算获得的频响与实测结果吻合程度良好,能够对系统频率响应函数进行较为准确的预测。该方法为后续开展时变动力学参数预测提供了初始模型基础,是实现薄壁件镜像铣削过程高精度稳定性预测和加工参数离线工艺优化的前提与方法支撑。

     

    Abstract: To address the challenge of accurately establishing a dynamic model for thin-walled workpiece systems in mirror milling, where complex boundary conditions from fixtures and active supports introduce significant inaccuracies, a high-fidelity dynamic modeling method based on S4R shell elements and a genetic algorithm is proposed to predict the dynamic characteristics of thin-walled workpiece-support systems in mirror milling under various clamping conditions. Based on a comparative mesh convergence analysis between S4R shell and C3D8R solid elements, the S4R shell element is selected to construct the initial dynamic model of the system, and the fixtures and the support equipment are modeled as equivalent spring elements to impose the boundary conditions. Using the error between the experimentally measured and simulated frequency response functions (FRFs) of the workpiece-support system as the objective function, a genetic algorithm is employed to identify the optimal values for parameters such as equivalent spring stiffness and modal damping ratios. The results demonstrate that the FRFs computed from the optimized shell element finite element model exhibit excellent agreement with the experimental results, enabling a more accurate prediction of the system's FRFs. The proposed method provides the foundational initial model for subsequent predictions of time-varying dynamic parameters, serving as a prerequisite and methodological support for the high-precision stability prediction and offline process optimization of the thin-walled workpiece mirror milling process.

     

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