Control of machining distortion stability in machining of monolithic aircraft parts

Fan, Longxin; Li, Liang; Yang, Yan; Zhao, Guolong; Han, Ning; Tian, Hui; He, Ning

doi:10.1007/s00170-021-06605-6

Cited by 8 publications

(5 citation statements)

References 28 publications

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“…Therefore, it can be argued that the cumulative effect of deformation on the lower surface exacerbates the final workpiece deformation, and by eliminating this deformation, processing-induced distortion can be controlled. This perspective is consistent with previous research [ 17 , 18 ].…”

Section: Resultssupporting

confidence: 94%

“…Moreover, researchers have proposed methods to correct the machining datum prior to precision machining to control deformation during subsequent processing. Research demonstrates that this approach effectively reduces final component deformation [ 17 , 18 ]. However, during the process of step-by-step milling from top to bottom, the deflection of the workpiece upper and lower surfaces varies.…”

Section: Resultsmentioning

confidence: 99%

“…Theoretical research provides the foundation and guidance for controlling machining deformation. Fan and Yang [ 17 , 18 ] proposed an optimization method based on the energy release mechanism during the machining process to improve the material removal sequence. This method suggests removing the high-strain energy material elements inside the workpiece during the rough machining stage and correcting the machining reference before the finish machining stage to effectively control deformation during subsequent machining.…”

Section: Introductionmentioning

confidence: 99%

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Prediction Model for the Evolution of Residual Stresses and Machining Deformation of Uneven Milling Plate Blanks

Zheng,

Hu,

Wang

et al. 2023

Materials

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During aerospace thin-walled component processing, the prediction and control of machining deformation have gained increasing attention. The initial residual stress in the blank is a major factor leading to the occurrence of machining deformation. This paper proposes the concept of uneven milling during the workpiece machining process, which is caused by the variation in local cutting depth resulting in uneven material removal thickness. Based on the elasticity theory, an analytical model is established to predict the evolution of overall residual stress and machining deformation in beam-like aluminum alloy components under uneven milling conditions. The effectiveness of the model is verified through finite element simulations and experiments. The results are as follows: (1) Under uneven milling conditions, the analytical model can accurately predict the distribution of residual stress and the machining deformation within the ZX section of the workpiece. (2) The uneven distribution of bending stress arises from the different curvature radii of various positions after workpiece deformation, leading to a 1 MPa to 3 MPa difference in stress between the middle and both ends of the workpiece. (3) During the layer-by-layer milling process, the magnitude of workpiece deformation is related to the stress state of the material removed, and there is a deformation superposition effect on the lower surface of the workpiece, further exacerbating the overall machining deformation.

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Section: Resultssupporting

confidence: 94%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Prediction Model for the Evolution of Residual Stresses and Machining Deformation of Uneven Milling Plate Blanks

Zheng,

Hu,

Wang

et al. 2023

Materials

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“…5. The material properties are listed in Table 1 (Fan et al, 2021). The crack compliance method (Yang et al, 2019) was used to determine the initial residual stress distribution.…”

Section: The Part Geometrymentioning

confidence: 99%

“…The findings show that residual stress and distortion can be effectively reduced by regulating and adjusting cutting depth. A technique to address the machining distortion stability brought on by the initial residual stress release during the machining process was put forth by Fan et al (2021). The findings demonstrate that the workpiece's stored strain energy can be sufficiently released in the initial stages of machining by optimizing the material removal sequence.…”

Section: Introductionmentioning

confidence: 99%

Machining distortion control of long beam parts based on optimal design of transition structure

Fan,

Han,

Zhang

2023

Mech. Sci.

Self Cite

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Abstract. In the machining of monolithic components, machining distortion is a severe issue. The presence of initial residual stress is a major contributor to machining distortion. This paper proposes an approach to control the machining distortion of long beam parts by optimizing the workpiece structure before the start of the finishing stage, i.e. the transition structure. The first step is to establish a machining distortion analytical model for long beam parts with an identical cross-section, which is based on reasonable assumptions such as material linear elasticity and ignoring the influence of cutting heat. Then, an optimization model for the cross-section of the transition structure is developed, with the objective function defined as the minimum difference between the predicted distortion of the final part and the transition structure. Finally, a U-shaped beam is designed, followed by numerical simulation and machining experiments for verification. The theoretical maximum distortion of the optimized transition structure and the final part are −0.174 and −0.1782 mm, respectively, with a relative error of 2.9 %. The results of machining experiments and finite-element simulation demonstrate the effectiveness of the proposed model.

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Simulation-Based Investigation of the Distortion of Milled Thin-Walled Aluminum Structural Parts Due to Residual Stresses

Weber¹,

Kirsch²,

D’Elia

et al. 2023

Proceedings of the 3rd Conference on Physical Modeling for Virtual Manufacturing Systems and Processes

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Nowadays, aluminum components in aircraft are mainly found in the form of thin-walled monolithic structural parts of the internal fuselage and the wings as spars and ribs [1]. This is because these components have excellent material properties for lightweight applications, such as a high strength-to-weight ratio and good corrosion resistance [2]. A typical manufacturing process to produce such structural components is milling. For these weight-optimized, monolithic components, up to 95% of the material is removed by machining [3]. The challenge with these thin-walled structural components, which are up to 14 m long, is that part distortion can occur because of the manufacturing-specific process chain [4]. Residual stresses due to machining and upstream processes such as forming, and heat-treatments are known to be the key factor for causing those distortions [5].In this research the effect of the residual stresses, the machining strategy, the part topology and the geometry, including the wall-thickness, on distortion were investigated experimentally, and simulatively by validated virtual models based on the finite-element method. Those models can then be used to predict the distortion. At the end distortion minimization techniques were derived.

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Control of machining distortion stability in machining of monolithic aircraft parts

Cited by 8 publications

References 28 publications

Prediction Model for the Evolution of Residual Stresses and Machining Deformation of Uneven Milling Plate Blanks

Prediction Model for the Evolution of Residual Stresses and Machining Deformation of Uneven Milling Plate Blanks

Machining distortion control of long beam parts based on optimal design of transition structure

Simulation-Based Investigation of the Distortion of Milled Thin-Walled Aluminum Structural Parts Due to Residual Stresses

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