Research on Finite Element Simulation and Parameters Optimization of Milling 7050-T7451 Aluminum Alloy Thin-walled Parts

Background: Thin-walled parts of aluminum alloy are easy to occur in machining deformation due to the characteristics of thin wall, low rigidity, and complex structure. Objective: To reduce and control the machining deformation, it is necessary to select reasonable machining parameters. Methods: The influence of milling parameters on the milling forces, milling temperature, and machining deformation was analyzed through the established model based on ABAQUS. Then, the corresponding empirical formula was obtained by MATLAB, and parameter optimization was carried out as well. Besides, a lot of patents on machining thin-walled parts were studied. Results: The results showed that the prediction error of milling forces is about 15%, and 20% of milling temperature. In this case, the optimized milling parameters are as follows: ap=1 mm, ae=0.1 mm, n=12 000 r/min, and f=400 mm/min. It is of great significance to reduce the machining deformation and improve the machining quality of thin-walled parts.