A novel in-process machining deformation perception and control method

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The machining deformation induced by redistribution of residual stresses is one of the biggest challenges of thin-walled parts manufacturing. For complex thin-walled part, the distribution of residual stresses after machining is so complex to accurately obtain. Therefore, as the basis of deformation control, the accuracy prediction of machining deformation can hardly achieve, especially for complex thin-walled part, which is restricted the development of deformation control method to some extent. In this paper, a novel perspective of in-process deformation perception method is firstly presented according to the energy conservation principle. Next, a hybrid clamping force perception-finite element simulation method is used to calculate the potential deformation of a fixed part. And then, a deformation control method by releasing the potential energy stored in the workpiece-fixture system in-processes is proposed to improve the machining accuracy. Finally, an instrumented fixture for blade parts is designed and two group machining experiments are carried out to verify the effectiveness of the proposed methods. The validation demonstrates a satisfactory agreement between the deformation measured through on-machine measurement system and calculated by the proposed perception method. Furthermore, the experimental results also indicate that the floating clamping method can reduce the deformation obviously.