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 cases 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 a theoretical model. Then, utilizing the semi-analytical model of equivalent bending stiffness, FEM simulation is carried out to analyze the influence of stiffening ribs on machining deformation. 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.
Highlights
With the rapid development of modern aviation industry, more and more aircraft monolithic components are applied in the big aircraft and fighter such as wing, girder and bulkhead in fuselage [1,2]
Analytical model of the machining deformation evolution is established based on the energy method
FEM is used to study the machining deformation of aircraft monolithic components combining with the equivalent stiffness
Summary
With the rapid development of modern aviation industry, more and more aircraft monolithic components are applied in the big aircraft and fighter such as wing, girder and bulkhead in fuselage [1,2]. Characteristics of aircraft monolithic components are large size, complex structure, and low stiffness because of the material removal rate of more than 93% Decrease deformation about 99.79% with step decrease iterative algorithm for the beam Machining sequence is another main factor that influences the initial residual stress redistribution during the machining process. Cerutti et al [10] studied the influence of the material removal sequence on the residual stress release in the machining deformation of aircraft monolithic components. We present a view that the conversion of energy can clarify this issue It is different from the above methods based on redistribution of initial residual stress. Initial residual stress of the blanks is converted into external load when the materials are removed, which leads to the deformation of the aircraft monolithic components after machining.
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