Computer simulation technique for drilling process of titanium alloy and composite material complex packages using digital twins

Abstract

Complex packages of polycrystalline composite materials based on carbon fiber plastics and titanium alloys find wide ap-plication in the designs of machine-building products and become the main material in the production of high-speed modern transport modes. However, the technology of machining parts surfaces made of these materials, namely holes, is character-ized by insufficient knowledge, lack of standards for cutting modes and is based more often on the production experience of enterprises. When machining conditions and materials of complex packages change, the duration of technological prepara-tion of production causes a significant increase in the cost of manufacturing components and parts due to the need for com-petent selection of rational elements of the cutting mode. To exclude the empirical fit of rational elements of the cutting mode on machining facility, the possibility of using digital twins of drilling processes in workpieces made of these materials is studied. It also implies the introduction of ultrasonic field energy into new surfaces generation of geometry in order to improve the quality of the machining area production efficiency and reduction of technological preparation of production based on the selection of elements of the cutting mode instead of testing the selected machining conditions using the existing technological equipment. The LS-DYNA program was used in the simulation process. Preparation of models and data pro-cess was carried out in the LS-Prepost 4.8 program. In the course of research, an explicit simulation technique with pre-liminary validation was used. Studies proved that the developed finite element models allow simulating the technological processes of simultaneous drilling of packages of titanium alloy and composite material in a computer (digital twin) without conducting sufficiently complex and costly field tests. Generated by simulation, a calculation sheet was obtained containing the simulation process, the solution of which visually reflects the process of drilling holes in workpieces made of complex packages of titanium alloy and composite material, as close as possible to the real situation with chip removal. Since the use of digital twins for performing this stage of technological preparation of production in the conditions of existing enterprises is not associated with a long and expensive operation of machine-tool fleet, we should expect a significant reduction in the cost of manufacturing components and parts from similar materials in industry, primarily in small-scale or single-part pro-duction.