scholarly journals Machining deformation analysis of aircraft monolithic components based on the energy method

Author(s):  
Xiaoming Huang ◽  
Xiaoliang Liu ◽  
Jiaxing Li ◽  
Yongbin Chen ◽  
Dechen Wei ◽  
...  
2021 ◽  
Author(s):  
Xiaoming Huang ◽  
Xiaoliang Liu ◽  
Jiaxing Li ◽  
Yongbin Chen ◽  
Dechen Wei ◽  
...  

Abstract In the process of machining aircraft monolithic components, the initial stress in the blank will cause machining deformation. Based on the energy method, an analytical mathematical model of machining deformation is presented in this paper. The key point is to transform the energy in the removed material into the deformation energy of the part after machining. The initial residual stress of 7050-T7451 aluminum alloy blank and single frame part are used as investigated case in the analytical model. For layer by layer machining, the deformation evolution is closely related to the tensile or compressive properties of the initial stress of removed material. Combined with the change of neutral axis position, The machining deformation is calculated by theoretical model. Then, FEM simulation is carried out to analyze the influence of stiffening ribs on machining deformation utilizing the semi-analytical model of equivalent bending stiffness. Furthermore, experiments are set up to verify the validity of the theory and FEM data. The results indicate that the deformation results of the experiment are consistent with that of theory and FEM model. Deformation is determined by energy of removed material. This paper provides a novel theoretical approaches for the further investigation of this issue.


2021 ◽  
Author(s):  
Xiaoming Huang ◽  
Xiaoliang Liu ◽  
Weitao Sun ◽  
Jiaxing Li ◽  
Yongbin Chen ◽  
...  

Abstract In the process of machining aircraft monolithic components, the initial stress in the blank will cause machining deformation. Based on the energy method, an analytical mathematical model of machining deformation is presented in this paper. The key point is to transform the energy in the removed material into the deformation energy of the part after machining. The initial residual stress of 7050-T7451 aluminum alloy blank and single frame part are used as investigated case in the analytical model. For layer by layer machining, the deformation evolution is closely related to the tensile or compressive properties of the initial stress of removed material. Combined with the change of neutral axis position, The machining deformation is calculated by theoretical model. Then, FEM simulation is carried out to analyze the influence of stiffening ribs on machining deformation utilizing the semi-analytical model of equivalent bending stiffness. Furthermore, experiments are set up to verify the validity of the theory and FEM data. The results indicate that the deformation results of the experiment are consistent with that of theory and FEM model. Deformation is determined by energy of removed material. This paper provides a novel theoretical approaches for the further investigation of this issue.


2011 ◽  
Vol 66-68 ◽  
pp. 569-572
Author(s):  
Hai Chao Ye ◽  
Guo Hua Qin ◽  
Cong Kang Wang ◽  
Dong Lu

Machining deformation has always been a bottleneck issue in the manufacturing field of aeronautical monolithic components. On the base of finite element method, the effect of the process steps and tool paths on the workpiece stiffness and the redistribution of residual stress in the machining process of aeronautical frame monolithic component was investigated under the given fixturing scheme. Thus, the prediction of the workpiece deformation can be carried out in reason. The proposed simulation approach to deformation analysis can be used to observe the true characteristic of milling forces and machining deformations. Therefore, the proposed method can supply the theoretical basis for the determination of the optimal process parameters.


2010 ◽  
Vol 97-101 ◽  
pp. 2894-2897 ◽  
Author(s):  
Zhi Tao Tang ◽  
Zhan Qiang Liu ◽  
Li Qiang Xu

When machining aerospace monolithic components, a severe deformation can be observed due to the release and redistribution of the original residual stresses, together with the action of cutting loads and clamping force. In this paper, a finite element model predicting machining deformation was developed considering the above mentioned multi-factors coupling effects. Based on the model, the effect of process routing on machining deformation for multi-frame double sided monolithic components was studied. To validate the FE model, true frame components were machined and deformations were measured on a Coordinate Measuring Machine. The result revealed that the prediction model is credible. At last the paper puts forwards optimal process routing based on minimizing the machining deformation.


2007 ◽  
Vol 24-25 ◽  
pp. 355-360 ◽  
Author(s):  
Zhi Tao Tang ◽  
Zhan Qiang Liu ◽  
Xing Ai

When machining aerospace monolithic components, most of materials could be removed, resulting in severe deformation of the parts due to the release and redistribution of the blank’s original residual stress, together with the action of cutting loads and clamping force. A finite element model (FEM) is built for predicting the deformation caused by those factors mentioned above. In this model, some key techniques such as material properties, initial residual stress model, and application of dynamic cutting loads and transformation of boundary condition are discussed in details. The proposed model predicts the machining deformation for multi-frame monolithic components. Particular attention is paid to the influence of the bulkhead processing sequence on part deformation. At last the paper puts forwards optimal bulkhead processing sequence based on minimizing the machining deformation.


2006 ◽  
Vol 315-316 ◽  
pp. 174-179 ◽  
Author(s):  
H. Guo ◽  
Dun Wen Zuo ◽  
S.H. Wang ◽  
Min Wang ◽  
L.L. Xu ◽  
...  

Many thin-walled structure components widely used in aero industries not only have complex structure and large size, but also need high machining accuracy. However, because of their poor rigidity, it is easy to bring machining deformation caused by the existence of the initial residual stresses, the fixing stresses, cutting forces and cutting heat. The difficulty in ensuring their machining accuracy becomes a big problem, so that how to effectively predict and control the machining deformation has become an important subject in the development and production of our national defense weapons. This paper established a 3-D Finite element model with consideration of milling forces, clamping forces and initial residual stress field. By using this model, machining deformation of thin-walled frame shape workpieces has been computed. The simulated results are compared with experimental data, and the correctness of the simulation is verified. The study is helpful to the prediction and the control of machining deformation for thin-walled parts.


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