【摘要】 针对航空发动机零件材料GH4065A高温合金难加工特性，开展数控榫槽拉刀结构设计的系统优化研究。采用有限元仿真与响应面法耦合的研究框架，基于AdvantEdge软件建立二维动态切削仿真模型，设定前角、后角、钝圆半径及齿升量四因素为变量，以切削力、切削温度和Mises应力分布为性能指标。采用Box-Behnken响应面设计法规划实验矩阵，通过29组仿真实验构建二阶多项式响应模型，量化参数间交互作用对切削性能的影响规律。最终求解综合性能最优的刀具参数组合，并通过残差分析与验证实验检验模型预测精度。得到GH4065A拉削加工的最优拉刀结构参数组合：前角为18.6°，后角为4.5°，钝圆半径为0.014 mm，齿升量为0.02 mm。结果表明：优化后的结构切削力、切削热和应力分布都得到较大改善；齿升量对切削力和切削热的影响最大，其次是刀具前角。更多还原

【Abstract】 In response to the challenging machining characteristics of GH4065A superalloy material used in aircraft engine components, this study conducted a systematic optimization research on the structural design of numerical control slot broaching tools. This study employs a research framework that combines finite element simulation and the response surface method. A two-dimensional dynamic cutting simulation model is established based on the AdvantEdge software,setting the rake angle, relief angle, fillet radius, and tooth rise as four variables, and taking the cutting force, cutting temperature, and von Mises stress distribution as performance indicators. The Box-Behnken response surface design method is adopted to plan the experimental matrix, and a second-order polynomial response model is constructed through 29 sets of simulation experiments to quantify the influence patterns of the interaction among parameters on cutting performance.Eventually, the combination of tool parameters with the optimal comprehensive performance is determined, and the prediction accuracy of the model is examined through residual analysis and verification experiments. This study ultimately acquires the optimal structural parameters of the broach for GH4065A broaching, namely a rake angle of 18. 6°, a relief angle of 4. 5°, a fillet radius of 0. 014 mm and a tooth rise of 0. 02 mm. The results demonstrated significant improvements in terms of cutting force, cutting temperature, and stress distribution after optimization. Rise per tooth exhibited the most substantial influence on both cutting force and cutting temperature, followed by the rake angle of the tool.更多还原