铣削工艺对钛合金轮盘表面残余应力影响规律

周惠敏; 刘宗晖; 李睿峰; 李果; 丁水汀

doi:10.13224/j.cnki.jasp.20250203

铣削工艺对钛合金轮盘表面残余应力影响规律

doi: 10.13224/j.cnki.jasp.20250203

周惠敏^1,,
刘宗晖²,
李睿峰³,
李果^4,*, ,,
丁水汀^{1, 5}

1.
北京航空航天大学航空发动机研究院，北京 100191
2.
中国航发湖南动力机械研究所结构强度研究部，湖南株洲 412002
3.
中国航天标准化研究所，北京 100071
4.
北京航空航天大学能源与动力工程学院，北京 100191
5.
中国民航大学，天津 300300

基金项目: 国家自然科学基金（U2233213）；中国博士后科学基金（2024M764100）；国家重大科技专项（MJG3-1N24）

详细信息

作者简介:
周惠敏（1993-），女，助理研究员，博士，主要从事航空发动机限寿件安全性与适航研究。E-mail：zhou_hm@buaa.edu.cn

通讯作者:
李果（1983-），男，教授，博士，主要从事航空发动机复杂系统安全性与适航研究。E-mail：09869@buaa.edu.cn

中图分类号: V232.3
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出版历程
- 收稿日期: 2025-04-27
- 网络出版日期: 2025-11-27

Effect of milling process on surface residual stress of titanium alloy disk

ZHOU Huimin^1
,,
LIU Zonghui²,
LI Ruifeng³,
LI Guo^{4,*
, ,},
DING Shuiting^{1, 5}

1.
Research Institute of Aero-engine，Beihang University，Beijing 100091，China
2.
Department of Structural Strength Research，Hunan Aviation Powerplant Research Institute，Aero Engine Corporation of China，Zhuzhou Hunan 412002，China
3.
China Astronautics Standards Institute，Beijing 100071，China
4.
School of Energy and Power Engineering，Beihang University，Beijing 100091，China
5.
Civil Aviation University of China，Tianjin 300300，China

摘要

摘要:
铣削作为轮盘加工的最后一道工序，引入的表面残余应力是航空发动机轮盘安全性设计的重要输入。克服了三维铣削结构复杂、网格生成和重新划分耗时、迭代周期长，二维铣削过于简化铣削变量的局限性，提出了考虑螺旋角的二维连续铣削仿真模型；进而，以实际钛合金限寿件铣削加工工艺参数为参照，偏离铣削工艺参数，并分析不同铣削主轴转速、铣削进给参数对残余应力的影响规律。结果表明：铣削工艺引入表面残余应力为压应力，量级为−20～−50 MPa，影响残余应力深度为0～100 μm；随着主轴转速的增加，表层残余压应力有减小趋势，而对残余压力层的层深几乎没有影响；随着进给量增加，表面残余压应力绝对值总体有增大趋势。
- 安全性与适航 /
- 钛合金轮盘 /
- 残余应力 /
- 二维连续铣削模型 /
- 正交切削
Abstract:
The surface residual stress induced by milling, which is the final machining process for aero-engine disks, is an important input for the safety design of aero-engine disks. The three-dimensional milling simulation is time-consuming because of geometry generation and remeshing, and the two-dimensional milling simulation oversimplifies variables of milling. To overcome the limitations of the three-dimensional and two-dimensional milling simulation, a two-dimensional continuous milling simulation model considering the helix angle was proposed. With reference to the actual milling process, deviations from the milling parameters were introduced, and the influence of spindle speeds and feed rates on residual stress was analyzed. The results showed that the surface residual stress induced by the milling process was compressive stress, with a magnitude of −20—−50 MPa, and the residual stress depth ranged from 0—100 μm. With the increase of the spindle speed, the surface residual compressive stress showed a decreasing trend, while the spindle speed had a minor effect on the residual stress depth. As the feed rate increased, the absolute value of the surface residual stress increased.
- safety and airworthiness /
- titanium alloy disk /
- residual stress /
- two-dimensional continuous milling model /
- orthogonal cutting

HTML

图 1 侧铣模型向斜角变厚度切削模型的转换过程

Figure 1. Conversion process from the milling model to the variable thickness cutting model for inclined angles

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图 2 斜角切削等效示意图

Figure 2. Equivalent method for oblique cutting

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图 3 铣削刀具角度测量及刀具角度示意图

Figure 3. Milling tool angle measurement and tool angle illustration

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图 4 刀具与工件的相对位置

Figure 4. Relative position between the tool and the workpiece

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图 5 工件与铣刀网格局部细化

Figure 5. Local enlarge view of grid of the tool and the workpiece

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图 6 铣削仿真边界条件（速度、位移、温度和换热）

Figure 6. Boundary condition of the milling process （velocity, displacement, temperature and heat transfer）

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图 7 铣削阶段

Figure 7. Milling step

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图 8 铣削表面残余应力分布（冷却前后）

Figure 8. Milling surface residual stress distribution （before and after cooling）

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图 9 残余应力路径选取

Figure 9. Path selection of residual stress

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图 10 铣削残余应力仿真结果

Figure 10. Simulation result of milling-induced residual stress

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图 11 验证算例及铣削残余应力结果云图

Figure 11. Verification case and the milling-induced residual stress

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图 12 主轴转速对表面残余应力的影响

Figure 12. Influence of spindle speed on surface residual stress

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图 13 主轴转速对深度方向残余应力分布的影响

Figure 13. Influence of spindle speed on residual stress along the machined surface depth

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图 14 每齿进给量对表面残余应力的影响

Figure 14. Influence of milling feed rate on surface residual stress

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图 15 每齿进给量对深度方向残余应力分布的影响

Figure 15. Influence of milling feed rate on residual stress along the machined surface depth

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表 1 钛合金Ti6Al4V的Johnson-Cook本构模型参数^[39]

Table 1. Parameters of the Johnson-Cook constitutive model for titanium alloy Ti6Al4V^[39]

A/MPa B/MPa C m n $ {{t}}_{\mathrm{melt}} $/℃ $ {{t}}_{\mathrm{0}} $/℃

843.8 785.6 0.033 0.841 0.26 1725 25

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表 2 铣削仿真方案

Table 2. Milling simulation case

序号主轴转速/
（r/min）每齿进给量/
（mm/r）铣削深度/
mm

1 2000 0.12 0.1

2 2500

3 3500

4 4000

5 2 000 0.10

6 0.18

7 0.24

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