Influence of cutting and clamping forces on machining distortion of diesel engine connecting rod

• Published in: International journal of advanced manufacturing technology 2018-10, Vol.99 (1-4), p.897-910
• Main Authors: Zhou, Honggen, Wang, Chuhui, Jing, Xuwen, Tian, Guizhong, Li, Guochao, Liu, Shan, Sun, Zhengkun
• Format: Article
• Language: English
• Subjects: CAE) and Design; Chip formation; Clamping; Computer simulation; Computer-Aided Engineering (CAD; Connecting rods; Cutting force; Deformation analysis; Deformation effects; Diesel engines; Engineering; Finite element method; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Media Management; Milling (machining); Model accuracy; Original Article; Process parameters; Residual stress; Rod milling; Simulation; Software; Superposition (mathematics); Unevenness
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-018-2436-5

As an important transmission component of diesel engines, the connecting rod has to meet a very high processing accuracy. However, as an elongated part, the connecting rod has a weak rigidity, and the unevenness of the cutting force and the clamping force during the machining processes will lead to the deformation of the connecting rod. In previous researches, cutting and clamping are always studied separately, and their interactions are neglected. In this paper, the finite element simulation method is used to analyze the deformation of the connecting rod. Based on the Deform-3D software, the article builds a connecting rod milling finite element simulation model and predicts the residual stress of the connecting rod milling simulation and the formation of milling chips. The residual stress of the simulation is compared with the residual stress of the experimental measurement and the simulation chip is compared with the actual chip to verify the accuracy of the simulation model, which provides a theoretical basis for the model construction of the next simulation study. Based on the Deform-3D software, simulation studies the influence of different milling parameters on the deformation of the connecting rods. And optimize the link milling process parameters. Based on ANSYS software, the effect of superposition of cutting force and clamping force on machining deformation of the connecting rod was simulated and analyzed. The resultant milling force should not be greater than 734N. This method makes up for the defects that cutting and clamping are studied separately and their interactions are neglected.