中国机械工程2025，Vol.36Issue(4)：770-779,10.DOI:10.3969/j.issn.1004-132X.2025.04.014
锥度球头刀四轴铣削TC4残余应力梯度分布反解
Inverse Solution for TC4 Residual Stress Gradient Distribution in Four-axis Milling with Tapered Ball-end Cutters
摘要
Abstract
The internal and external profile finishing of the metal reinforcing edges of the leading edge of large composite fan blades for commercial aero-engines was accomplished by four-axis milling with a customized taper ball-end cutter,and the machining residual stresses introduced at this stage often caused excessive bending and torsional deformations leading to dimensional overshoots of the parts.For the four-axis milling of titanium alloy TC4 with taper ball-end cutter,an inverse identifica-tion method of milling residual stress gradient distribution was proposed based on the deformation tests of thin plate machining herein.The hyperbolic tangent models were used to parametrically char-acterize the milling residual stress gradient distribution,and the solution of the residual stress gradi-ent distribution was converted into the inverse solution of two pending coefficients k and ω.The model coefficient k was determined by testing the residual stress on the machined surfaces of the titanium al-loy specimen blocks,and the model coefficient ω was inversely solved by testing the bending deforma-tion deflection of milled titanium alloy thin plates,then the residual stress gradient distribution curve was determined.Four groups of titanium alloy TC4 test block milling validation experiments were car-ried out,and the test results show that the average prediction accuracy of the milling residual stress gradient distribution is as high as 99.35％.Compared with the traditional X-ray test method,the pro-posed method avoids the use of electrolytic corrosion stripping to test the subsurface residual stresses,and also takes into full consideration the non-uniformity of the distribution of milling residual stresses on the machined surfaces,namely the problem of the dispersion of milling residual stresses.关键词
锥度球头刀/钛合金TC4/四轴铣削/残余应力/逆向辨识/离散度Key words
tapered ball-end cutter/titanium alloy TC4/four-axis milling/residual stress/re-verse identification/dispersion分类
航空航天引用本文复制引用
周金华,齐琪,任军学,詹梅..锥度球头刀四轴铣削TC4残余应力梯度分布反解[J].中国机械工程,2025,36(4):770-779,10.基金项目
航空发动机及燃气轮机基础科学中心重点项目(P2022-B-Ⅳ-012-001) （P2022-B-Ⅳ-012-001）
国家自然科学基金(52475488,52075451) （52475488,52075451）
国家重点研发计划(2022YFB3709100) （2022YFB3709100）
陕西省自然科学基础研究计划(2024JC-YBMS-288) （2024JC-YBMS-288）
