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

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Abstract

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.

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Funding

This study was supported by the 2020 Open Project of the National Key Laboratory of Helicopter Transmission Technology (Project grant no.: 4HTL-O-20G04).

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Authors and Affiliations

  1. School of Mechanical Engineering, Yancheng Institute of Technology, Hope Avenue Road 1, Tinghu District, Yancheng, Jiangsu Province, 224051, People’s Republic of China

    Haixiang Huan, Ke Zhang, Wenqiang Xu & Mengxiong Wang

  2. National Key Laboratory of Science and Technology On Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Jiuhua Xu

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  1. Haixiang Huan
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  2. Ke Zhang
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  3. Jiuhua Xu
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  4. Wenqiang Xu
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  5. Mengxiong Wang
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Contributions

All authors contributed to the study concept and design. The project declaration was conducted by J.X., and the material preparation, data collection, and analysis were conducted by H. H., K.Z. and W.X. The first draft of the manuscript was written by K.Z., the formatting of the paper was revised, the English statements were touched up by M.W., and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Haixiang Huan.

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Huan, H., Zhang, K., Xu, J. et al. Machining deformation control methods and analysis of a thin-walled gear spoke plate. Int J Adv Manuf Technol 127, 1317–1331 (2023). https://doi.org/10.1007/s00170-023-11609-5

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  • DOI: https://doi.org/10.1007/s00170-023-11609-5

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