Abstract
Machining distortion is a major issue in the machining of thin-walled monolithic components, which are now widely used in the aerospace industry. The evolution of the stress field within the workpiece during machining (due to material removal and cutting loads) is the main cause of global machining distortion for thin-walled parts. This paper presents a new modeling method for machining distortion that can represent this stress evolution process. The finite element method (FEM) is used to model the material removal and mechanical loads during roughing. Theoretical modeling is used to model the influence of finishing on stress redistribution within surface material. Finally, FEM is used to calculate the machining distortion. This method can be implemented on small servers and personal computers. An application case of a thin-walled component was considered. The simulation result with the new method showed superior accuracy compared with traditional simulation method. The method presented could be used to predict the machining distortion for parts, which would allow further improvement in machining techniques.
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