The Application of FEM Technology on the Deformation Analysis of the Aero Thin-Walled Frame Shape Workpiece

2006 ◽  
Vol 315-316 ◽  
pp. 174-179 ◽  
Author(s):  
H. Guo ◽  
Dun Wen Zuo ◽  
S.H. Wang ◽  
Min Wang ◽  
L.L. Xu ◽  
...  
Keyword(s):  
Complex Structure ◽  
Element Model ◽  
Deformation Analysis ◽  
Machining Accuracy ◽  
National Defense ◽  
Residual Stress Field ◽  
Machining Deformation ◽  
Thin Walled ◽  
And Control ◽  
Milling Forces

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.

Research on Finite Element Simulation and Parameters Optimization of Milling 7050-T7451 Aluminum Alloy Thin-walled Parts

2020 ◽  
Vol 14 ◽  
Author(s):  
Song Yang ◽  
Tie Yin ◽  
Feiyue Wang
Keyword(s):  
Aluminum Alloy ◽  
Complex Structure ◽  
Parameters Optimization ◽  
Thin Wall ◽  
Machining Parameters ◽  
Milling Parameters ◽  
Machining Deformation ◽  
Milling Temperature ◽  
Thin Walled ◽  
Milling Forces

Background: Thin-walled parts of aluminum alloy are easy to occur machining deformation duo to the characteristics of thin wall, low rigidity, and complex structure. Objective: To reduce and control the machining deformation, it is necessary to select reasonable machining parameters. Method: The influence of milling parameters on the milling forces, milling temperature, and machining deformation was analyzed through the established model based on ABAQUS. Then, the corresponding empirical formula was obtained by MATLAB, and parameters optimization was carried out as well. Besides, a lot of patents on machining thin-walled parts were studied. Results: The results shown that the prediction error of milling forces is about 15%, and 20% of milling temperature. In this case, the optimized milling parameters are as follows: ap=1 mm, ae=0.1 mm, n=12 000 r/min, and f=400 mm/min. It is of great significance to reduce the machining deformation and improve the machining quality of thin-walled parts.

Deformation Analysis of Thin-Walled Workpiece under Multi-Stress Coupled Effect

2010 ◽  
Vol 426-427 ◽  
pp. 284-288
Author(s):  
Dong Lu ◽  
Guo Hua Qin ◽  
Yi Ming Rong ◽  
C.M. Peng
Keyword(s):  
Initial Stress ◽  
Coupled Model ◽  
Element Model ◽  
Milling Process ◽  
Machining Process ◽  
Deformation Analysis ◽  
Milling Force ◽  
Thin Walled ◽  
And Control ◽  
The Finite Element Model

This document Cutting stress coupled with clamping stress and initial stress affects the workpiece deformation. To analyze the workpiece deformation the initial stress model is developed. The finite element model of milling process is established and the milling force and milling heat is predicted. The multi-stress coupled model is developed and the workpiece deformation during machining process and deformation after fixtures released are predicted. This study is helpful to predict and control the deformation for thin-walled workpiece.

Macro-Residual Stress Field Retrieval for Predicting the Machining Deformation of Non-Prestretched Plate

2011 ◽  
Vol 317-319 ◽  
pp. 386-392
Author(s):  
Yin Fei Yang ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Large Scale ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Hole Drilling Method ◽  
Machining Deformation ◽  
Stress Changes ◽  
Drilling Method ◽  
And Control

The unknown and uneven macro-residual stresses in blanks will cause deformation on large-scale component, especially in non-prestretched plates. Based on the retrieval of stress field by measuring stress changes due to the rebalance of stresses after machining, a new idea is proposed in this paper to predict and control the machining deformation of large-scale components. It consists of analysis of the machining deformation, retrieval of macro-residual stress field, and finally optimization of following cutting process. In the retrieval process, the stresses are measured with an improved hole-drilling method and the measured data are then interpolated to 3D stress field.

Turning Thermal Deformation Analysis of Aluminum Alloy Spherical Plain Bearing Outer Ring

2014 ◽  
Vol 556-562 ◽  
pp. 733-737
Author(s):  
Yan Jun Li ◽  
Bao Fu Li
Keyword(s):  
Aluminum Alloy ◽  
Element Model ◽  
Outer Ring ◽  
Deformation Analysis ◽  
Machining Accuracy ◽  
Plain Bearing ◽  
Axial Deformation ◽  
Machining Error ◽  
Deformation Law ◽  
Spherical Plain Bearing

Against the problem of large machining error and low productivity of aluminum alloy spherical plain bearing, the paper is concentrated on building finite element model in MATLAB to research the radial and axial deformation law under various cutting conditions with theories of heat transfer, isoparametric element and functional variational method, providing theoretical and data support to enhance machining accuracy of spherical plain bearing outer ring.

Analysis of 45 Steel Rectangular Thin-Walled Parts Milling Deformation

2015 ◽  
Vol 667 ◽  
pp. 22-28 ◽  
Author(s):  
Jing Li ◽  
Zhan Li Wang ◽  
Ping Xi ◽  
Yang Jiao
Keyword(s):  
Prediction Model ◽  
Three Dimensional ◽  
Material Model ◽  
Machining Accuracy ◽  
Machining Deformation ◽  
Dimensional Finite Element ◽  
Prediction And Control ◽  
Length Direction ◽  
Thin Walled ◽  
Three Dimensional Finite Element

Aiming at the problem that the machining accuracy of 45 steel rectangular thin-walled parts are difficult to ensure because of poor rigidity, poor manufacturability and easy machining deformation, it used the three-dimensional finite element method, determined the material model of 45 steel and established a prediction model of 45 steel rectangular thin-walled parts milling deformation. The prediction results display that the deformation of the workpiece shows obvious parabola in length direction and a linear decreasing trend in width direction. It verifies the correctness of the prediction model through milling experiments and provides the method and basis for the prediction and control of machining deformation of 45 steel thin-walled parts.

scholarly journals Study on the stress of micro-S-shaped folding cantilever

2020 ◽  
Vol 12 (5) ◽  
pp. 168781402092486 ◽  
Author(s):  
Shuangjie Liu ◽  
Yongping Hao ◽  
Xiannan Zou
Keyword(s):  
Finite Element ◽  
Theoretical Model ◽  
Complex Structure ◽  
Element Model ◽  
Theoretical Formula ◽  
Yield Limit ◽  
Force Analysis ◽  
Micro Cantilever ◽  
And Control ◽  
The Finite Element Model

Micro-cantilever has shown wide application prospect in the field of micro-sensors, actuators, gyroscope, and so on. There are abundant research studies on simple cantilever beam models, but there are few on S-shaped folding cantilever with complex structure, although it is widely used. In order to study the deformation failure of S-shaped folding cantilever, the force analysis of S-shaped folding cantilever was carried out in this article, and the stress values of different positions under the external load of the cantilever were deduced. The finite element model about S-shaped folding cantilever was built based on software ANSYS. The theoretical calculation was compared with the finite element calculation, and the results showed that the max stress is 681 MPa based on the derived theoretical formula, the max stress is 673 MPa based on the ANSYS, the error is 1.18%, which can prove formula is accurate. To further validate the stress predicted by the mathematical modeling, a micro-force testing platform was built to test the cantilever. Since the stress value cannot be measured directly in the test, the force corresponding to the stress was taken as standard and compared it with the simulation. The tested external force was corresponding the yield limit. The results showed that the experimental force was 0.06462 N before the plastic deformation occurred, the theoretical outcome was 0.065231 N corresponding the yield limit, the error was 0.94%. Both simulation and experimental results depict that the theoretical model is effective for predicting the stress of the S-shaped folded cantilever. The theoretical model helps to enhance the efficiency, and improve the performance, predictability, and control of the S-shaped folding cantilever.

Deformation Analysis of Aero Thin-Walled Workpiece Under Multi-Stress Coupled Effect

2007 ◽  
Author(s):  
Dong Lu ◽  
Jianfeng Li ◽  
Yiming Rong ◽  
Jie Sun ◽  
Song Zhang ◽  
...  
Keyword(s):  
Initial Stress ◽  
Initial Conditions ◽  
Stable Condition ◽  
Coupled Model ◽  
Element Model ◽  
Milling Process ◽  
Deformation Analysis ◽  
Reaction Forces ◽  
Milling Forces ◽  
The Finite Element Model

Cutting stress coupled with clamping stress and initial stress affects the workpiece deformation. To predicate the workpiece deformation during machining, the multi-stress coupled model was developed. The finite element model of milling process is established and the milling forces were predicted. The predicated milling force, clamping force and initial stress were taken as initial conditions and were inputted into the multi-stress coupled model. Workpiece deformation during machining and reaction forces of locators were predicated. To maintain workpiece in a stable condition during machining, reaction forces of the locators when the cutting tool moving along the clamp side must be monitored.

Machining Allowance Optimal Distribution of Thin-Walled Structure Based on Deformation Control

2017 ◽  
Vol 868 ◽  
pp. 158-165 ◽  
Author(s):  
Yu Zhi Chen ◽  
Wei Fang Chen ◽  
Rui Jun Liang ◽  
Ting Feng
Keyword(s):  
Cutting Force ◽  
Element Model ◽  
Optimization Method ◽  
Milling Process ◽  
Machining Process ◽  
Machining Accuracy ◽  
Side Milling ◽  
Deformation Control ◽  
Thin Walled ◽  
Relationship Of

Multilayer cutting is widely used in finish machining process of thin-walled parts to improve the machining precision. The paper presents a cutting allowance optimization method using genetic algorithm to improve the machining quality and efficiency of thin-walled parts in the field of aerospace. Considering the coupling relationship of the deformation between the layers in layered milling, the parameterized finite element model of thin-walled parts in side milling process is established. The best relationship between the workpiece stiffness and the cutting force is determined though iterative calculations, and the deformation caused by the cutting force can be minimized. The results show that the optimized distribution of the depth of finishing cutting was better than the experience. The method proposed in this paper can reduce the deformation of the workpiece during the machining process, and thus improve the machining accuracy.

scholarly journals Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Zhenjing Duan ◽  
Changhe Li ◽  
Wenfeng Ding ◽  
Yanbin Zhang ◽  
Min Yang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Research Progress ◽  
Machining Accuracy ◽  
Force Model ◽  
Milling Force ◽  
Thin Walled ◽  
Milling Forces ◽  
Milling Force Model

AbstractAluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In view of these problems, the future work direction is proposed in the following four aspects: (1) high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth, which easily produces high residual stress. The residual stress should be analyzed under this particular condition. (2) Multiple factors (e.g., eccentric swing milling parameters, lubrication conditions, tools, tool and workpiece deformation, and size effect) should be considered comprehensively when modeling instantaneous milling forces, especially for micro milling and complex surface machining. (3) The database of milling force model, including the corresponding workpiece materials, working condition, cutting tools (geometric figures and coatings), and other parameters, should be established. (4) The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling. (5) The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication (mql) and nanofluid mql should be predicted.

Predictive Modeling for Distortion in Large, Thin-Walled Machined Components

2011 ◽  
Vol 223 ◽  
pp. 56-65
Author(s):  
Abhik Rakshit ◽  
Shuji Usui ◽  
Troy D. Marusich ◽  
Kerry Marusich ◽  
Luis Zamorano ◽  
...  
Keyword(s):  
Predictive Modeling ◽  
Material Removal ◽  
Element Model ◽  
Optimum Material ◽  
Machine Parts ◽  
Thin Walled ◽  
And Performance ◽  
And Control ◽  
Monolithic Structures ◽  
Typical Solution

Machining of large monolithic structures is standard practice in today’s aerospace world. Driven by cost and performance, it is becoming necessary for airframe manufacturers to machine parts better, faster, lighter, and cheaper than ever before. When machining these large monolithic structures, however, distortion becomes a significant problem. The typical solution to this problem is to machine with lower than optimum material removal rates, and perform additional fixture rotations – both of which add unnecessary time and cost to the manufacturing process. A finite element model has been developed specifically to predict and control these distortions. The model takes into consideration the machining-induced residual stresses, as well as the bulk stresses in the material from the manufacturer.

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