In the field of mechanical parts customization, thin-walled parts often experience deformation during machining due to their poor structural rigidity and susceptibility to cutting forces and thermal stresses. This directly impacts part precision and assembly performance. To reduce deformation risk through process improvements, comprehensive measures must be implemented, encompassing cutting parameter optimization, innovative clamping methods, machining path planning, tool selection, and thermal stress control, to enhance process stability and product quality.
Appropriate selection of cutting parameters is key to controlling deformation in thin-walled parts. In mechanical parts customization, excessive depth of cut or high feed rates during thin-walled part machining can lead to a sudden increase in cutting forces, causing elastic or even plastic deformation. Reducing the depth of cut, increasing the feed rate, and optimizing the spindle speed can significantly reduce cutting forces per unit area. For example, employing a "light cutting" strategy of small-diameter tools combined with high speed and low feed rates can ensure machining efficiency while minimizing the impact of cutting forces on thin-walled structures. Furthermore, the application of a staged cutting process is crucial: leaving appropriate allowances during roughing and gradually removing material during finishing to avoid stress concentration caused by excessive cutting volume at one time.
Innovative clamping design directly impacts the machining stability of thin-walled parts. Traditional vise clamping can easily cause localized deformation of thin-walled parts due to uneven clamping force. However, vacuum chuck or magnetic clamping technologies effectively reduce stress concentration on the workpiece by distributing the clamping force. Customized flexible fixtures are more widely used for irregularly shaped thin-walled parts. These can adjust the clamping point position and pressure according to the part contour, ensuring the workpiece maintains a stable position during machining. For example, in the customized machining of thin-walled aerospace brackets, the use of multi-point elastic support fixtures can minimize workpiece deformation while avoiding surface indentations caused by rigid clamping.
Optimizing machining paths is an effective means of reducing thermal deformation in thin-walled parts. In mechanical parts customization, continuous cutting can easily lead to localized temperature increases, causing thermal stress and deformation. Using a ramp-type or spiral-type feed path can disperse cutting heat generation and avoid heat concentration. Furthermore, combining dry cutting with minimal lubrication technology can reduce the impact of cutting fluid on the workpiece while also reducing frictional heat generation through lubrication. For example, in the custom machining of thin-walled stainless steel sleeves, dry cutting combined with low-temperature compressed air cooling can improve workpiece surface temperature uniformity and significantly reduce the risk of thermal deformation.
Adaptive tool geometry is crucial for the machining accuracy of thin-walled parts. In mechanical parts customization, thin-walled parts require tools with large rake angles and small clearance angles to reduce cutting resistance and heat generation. Furthermore, tool edges should be passivated to prevent vibration caused by micro-chipping caused by sharp cutting edges. For high-precision thin-walled parts, solid carbide or coated tools can be used. Their high rigidity and wear resistance effectively suppress machining vibration. For example, in the custom machining of thin-walled titanium alloy impellers, the use of PCD polycrystalline diamond tools can reduce surface roughness and minimize dimensional deviation caused by tool wear.
Thermal stress control is a crucial step in thin-walled part machining. In mechanical parts customization, a stress relief process, such as natural aging or vibration aging, is required between roughing and finishing to eliminate residual stresses generated during machining. Furthermore, stable control of the machining environment temperature is crucial. A constant temperature workshop can minimize workpiece expansion and contraction caused by temperature differences. For example, in the custom processing of thin-walled precision optical parts, maintaining the workshop temperature within a specified range can improve workpiece dimensional stability and reduce assembly errors caused by thermal deformation.
Increasing the rigidity of the process system is the fundamental way to reduce vibration in thin-walled parts. In mechanical parts customization, the rigidity of the machine tool spindle, guideways, and fixtures directly impacts machining stability. Selecting high-rigidity CNC machine tools and optimizing machine parameter settings can reduce vibration transmission during machining. For example, in a five-axis machining center, adjusting the spindle dynamic balance and servo system response speed can reduce vibration amplitude during thin-walled part machining and significantly improve surface quality.
In mechanical parts customization, reducing the risk of thin-walled part deformation requires multi-dimensional process improvements. From cutting parameters to clamping methods, from tool selection to thermal stress control, optimization of each step must be closely integrated with part material properties and structural requirements. Through systematic process improvements, we can achieve high precision, high efficiency and high stability in thin-walled parts processing, providing more competitive solutions for the field of mechanical parts customization.
