Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell
Abstract Due to its challenging manufacturing and intricate morphology, the aluminum alloy transmission intermediate shell used in vehicle transmission has been the focus of many academic studies. In this study, the three-dimensional cutting model is condensed to a two-dimensional cutting model and...
| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
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Nature Portfolio
2024-02-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-024-54552-5 |
| _version_ | 1797275093412347904 |
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| author | Haiyue Zhao Yan Cao Yu Bai Hui Yao Chunlei Tian |
| author_facet | Haiyue Zhao Yan Cao Yu Bai Hui Yao Chunlei Tian |
| author_sort | Haiyue Zhao |
| collection | DOAJ |
| description | Abstract Due to its challenging manufacturing and intricate morphology, the aluminum alloy transmission intermediate shell used in vehicle transmission has been the focus of many academic studies. In this study, the three-dimensional cutting model is condensed to a two-dimensional cutting model and utilized to simulate the finishing process of an aluminum alloy workpiece using the finite element modeling program DEFORM-3D. Through orthogonal testing and range analysis, the impact of integral end mill side edge parameters on cutting performance was investigated. It is determined that tool chamfering has a greater impact on cutting performance than tool rake and relief angles, that chamfering width has the most impact on cutting force, and that chamfering angle has the greatest impact on cutting temperature. The workpiece's surface roughness is tested during a cutting experiment, and an analysis of the data reveals that the finite element simulation model is accurate and the orthogonal test method is reasonable. The tool chamfer has a greater impact on roughness than the tool rake angle and relief angle. The tool settings are further optimized using the firefly method. By examining the data, it is determined that the prediction model is correct and the optimization model is reasonable. The cutting efficiency is higher and the surface quality is better when the chamfer width is 0.17 mm and the chamfer angle is 7.3° or 18.3°. Therefore, optimizing the side edge parameters of the integral end mill during the finishing process of a thin-walled aluminum alloy shell has practical technical value. |
| first_indexed | 2024-03-07T15:08:30Z |
| format | Article |
| id | doaj.art-b8689c19aad641ea8b1e5d2b21144f9f |
| institution | Directory Open Access Journal |
| issn | 2045-2322 |
| language | English |
| last_indexed | 2024-03-07T15:08:30Z |
| publishDate | 2024-02-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj.art-b8689c19aad641ea8b1e5d2b21144f9f2024-03-05T18:48:27ZengNature PortfolioScientific Reports2045-23222024-02-0114111310.1038/s41598-024-54552-5Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shellHaiyue Zhao0Yan Cao1Yu Bai2Hui Yao3Chunlei Tian4School of Mechatronic Engineering, Xi’an Technological UniversitySchool of Computer Science and Engineering, Xi’an Technological UniversitySchool of Mechatronic Engineering, Xi’an Technological UniversitySchool of Mechatronic Engineering, Xi’an Technological UniversitySchool of Mechatronic Engineering, Xi’an Technological UniversityAbstract Due to its challenging manufacturing and intricate morphology, the aluminum alloy transmission intermediate shell used in vehicle transmission has been the focus of many academic studies. In this study, the three-dimensional cutting model is condensed to a two-dimensional cutting model and utilized to simulate the finishing process of an aluminum alloy workpiece using the finite element modeling program DEFORM-3D. Through orthogonal testing and range analysis, the impact of integral end mill side edge parameters on cutting performance was investigated. It is determined that tool chamfering has a greater impact on cutting performance than tool rake and relief angles, that chamfering width has the most impact on cutting force, and that chamfering angle has the greatest impact on cutting temperature. The workpiece's surface roughness is tested during a cutting experiment, and an analysis of the data reveals that the finite element simulation model is accurate and the orthogonal test method is reasonable. The tool chamfer has a greater impact on roughness than the tool rake angle and relief angle. The tool settings are further optimized using the firefly method. By examining the data, it is determined that the prediction model is correct and the optimization model is reasonable. The cutting efficiency is higher and the surface quality is better when the chamfer width is 0.17 mm and the chamfer angle is 7.3° or 18.3°. Therefore, optimizing the side edge parameters of the integral end mill during the finishing process of a thin-walled aluminum alloy shell has practical technical value.https://doi.org/10.1038/s41598-024-54552-5Thin-walled parts shellNumerical simulationTool parameters optimizationCutting experimentFirefly algorithm |
| spellingShingle | Haiyue Zhao Yan Cao Yu Bai Hui Yao Chunlei Tian Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell Scientific Reports Thin-walled parts shell Numerical simulation Tool parameters optimization Cutting experiment Firefly algorithm |
| title | Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| title_full | Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| title_fullStr | Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| title_full_unstemmed | Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| title_short | Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| title_sort | numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell |
| topic | Thin-walled parts shell Numerical simulation Tool parameters optimization Cutting experiment Firefly algorithm |
| url | https://doi.org/10.1038/s41598-024-54552-5 |
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