Numerical simulation and tool parameters optimization of aluminum alloy transmission intermediate shell

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Aluminum alloy transmission shells present manufacturing challenges due to complex shapes.
• Optimizing machining processes is crucial for improving efficiency and surface quality.

Purpose of the Study:

• To investigate the impact of integral end mill side edge parameters on the finishing of aluminum alloy workpieces.
• To optimize tool parameters for enhanced cutting performance and surface quality.

Main Methods:

• Finite element modeling (DEFORM-3D) was used to simulate the 2D cutting process.
• Orthogonal testing and range analysis were employed to study parameter effects.
• The firefly optimization algorithm was utilized for parameter tuning.

Main Results:

• Tool chamfering parameters (width and angle) significantly influence cutting force, temperature, and surface roughness.
• Chamfer width had the most impact on cutting force, while chamfer angle most affected cutting temperature.
• Optimal cutting efficiency and surface quality were achieved with a chamfer width of 0.17 mm and angles of 7.3° or 18.3°.

Conclusions:

• The finite element simulation and orthogonal test methods are validated for accuracy and reasonableness.
• Optimizing integral end mill side edge parameters offers practical value for thin-walled aluminum alloy shell finishing.
• Tool chamfering is more critical than rake and relief angles for improving surface roughness.