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Characteristics of shear stress based on magnetorheological fluid flexible fixture during milling of the thin-walled part

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Abstract

With light weight and good overall structure, thin-walled part has been widely used in various fields like aerospace. However, it has low stiffness in the cutting process. Traditional fixture clamping workpiece has a long positioning and adjustment cycle and is likely to deform, making it difficult to control machining efficiency and quality. In this study, a mechanical-magnetorheological fluid (MRF) composite flexible clamping method was proposed, and a theoretical mathematical model of the shear stress of MRF was constructed. The real value and the theoretical value of shear stress show consistent upward and downward trends. Based on the prediction model, the coupling relations between magnetic field intensity and thickness and position of workpiece were studied. Results demonstrate that workpiece thickness has less significant influence on shear stress compared with workpiece position. Combined with the experimental results, the smaller the workpiece thickness and the closer to the magnetic field, the larger the shear stress. The shear stress of the workpiece 1 mm thick is 21.5% higher than that of the workpiece with the thickness of 8 mm at position of 10 mm. Finally, the thin-walled part was used to demonstrate MRF clamping. Compared with the traditional clamping method, the proposed method can decrease the cutting force by 14.3%. Moreover, the residual stress σx and σy decrease by 37.0% and 43.9%, the flatness value decreases by 55.6%, and the roughness Ra, Rz and Rq decrease by 55.6%, 53.2%, and 56.7%. The quality of the thin-walled part was effectively controlled.

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Funding

This project is supported by the Innovation Funding of Shanghai Aerospace Science and Technology (Grant No. SAST2019-065) and the Shanghai Science and Technology Commission (Grant No. 19060502300).

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Authors and Affiliations

  1. College of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai, 200093, China

    Jiang Xiaohui, Zhang Yong, Lu Weiwei & Gao Shan

  2. School of Mechanical and Electronical Engineering, Lanzhou University of Technology, Lanzhou, 730050, China

    Liu Ling

  3. Shanghai Aerospace Equipment Manufacturing Company Limited, Shanghai, China

    Liu Xiao

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  1. Jiang Xiaohui
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  2. Zhang Yong
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  3. Lu Weiwei
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  4. Gao Shan
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  5. Liu Ling
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  6. Liu Xiao
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Correspondence to Jiang Xiaohui.

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Xiaohui, J., Yong, Z., Weiwei, L. et al. Characteristics of shear stress based on magnetorheological fluid flexible fixture during milling of the thin-walled part. Int J Adv Manuf Technol 108, 2607–2619 (2020). https://doi.org/10.1007/s00170-020-05439-y

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  • DOI: https://doi.org/10.1007/s00170-020-05439-y

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