Abstract
The deformation of aeronautical monolithic components due to CNC machining is a bottle-neck issue in the aviation industry. The residual stress releases and redistributes in the process of material removal, and the distortion of the monolithic component is generated. The traditional one-side machining method will produce oversize deformation. Based on the three-stage CNC machining method, the quasi-symmetric machining method is developed in this study to reduce deformation by symmetry material removal using the M-symmetry distribution law of residual stress. The mechanism of milling deformation due to residual stress is investigated. A deformation experiment was conducted using traditional one-side machining method and quasi-symmetric machining method to compare with finite element method (FEM). The deformation parameters are validated by comparative results. Most of the errors are within 10%. The reason for these errors is determined to improve the reliability of the method. Moreover, the maximum deformation value of using quasi-symmetric machining method is within 20% of that of using the traditional one-side machining method. This result shows the quasi-symmetric machining method is effective in reducing deformation caused by residual stress. Thus, this research introduces an effective method for reducing the deformation of monolithic thin-walled components in the CNC milling process.
Highlights
Whole aeronautic thin-walled structures produced by various methods are widely used in aerospace technology, especially produced by machining methods
The current paper presents the quasi-symmetric machining method and finite element method (FEM) to reduce deformation caused by residual stress
The influence thepaper clamping scheme deformation caused by releasing and redistribution of residual stress for aeronautical monolithic distortion is negligible in CNC machining processes
Summary
Whole aeronautic thin-walled structures produced by various methods are widely used in aerospace technology, especially produced by machining methods. Wang et al [4] made a similar point that when machining thin-walled aeroplane parts, more than 90% of the material would be removed, resulting in severe distortion of the parts due to the weakened rigidity and the release of residual stress. Ocana et al [13] presented a model to provide a predictive estimation of the residual stress and surface deformation induced by laser action relevant for analysis the influence of different parameters in the milling process. The current paper presents the quasi-symmetric machining method and FEM to reduce deformation caused by residual stress. The current paper presents the quasi-symmetric machining method to reduce deformation by symmetrical material removal using the M-symmetry distribution law of residual stress. The quasi-symmetric machining method is validated as a reliable and effective method in reducing deformation caused by residual stress
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