Study on Machining Deformation of Aircraft Monolithic Component by FEM and Experiment

Machining deformation of aircraft monolithic component is simulated by finite element method （FEM） and validated by experiment. The initial residual stress in pre-stretched plate is generated by simulating quenching and stretching processes. With a single tool-tooth milling process FEM, the machining loads in monolithic component material removing is obtained. Restart-calculation is put forward to complete the whole simulation of machining process. To verify the FEM result, an experiment is carried out. The deformation distribution of the monolithic component resulting from FEM shows a good agreement with the experiment result, which indicates that the key technologies presented in the paper are practicable and can be used to simulate the milling process of monolithic component to predict its deformation. Lengthy and expensive trial and error experiment process can be avoided.

Simulation and Verification of Machining Deformation for Composite Materials

Prepreg properties including cure kinetics, cure shrinkage, and coefficient of thermal expansion were analyzed. A simulation method based on ＂element birth and death＂ method of Finite element analysis （FEA） was presented to simulate the cutting process and predict the machining deformation for composite laminates and stiffened panels. The comparisons between the simulation results and experimental data showed good agreement. It is found that residual stresses are the main source of machining deformation for composites and machining deformation is expected to happen only if there are stress gradients along the machining direction. There is no machining deformation for composite laminates due to its uniform stresses distribution in plane, while machining deformation can be observed obviously for T-shape stiffened composite panels. Attention should be paid to machining deformation to avoid the mismatch during assembly.

Machining Deformation Prediction of Thin-Walled Part Based on Finite Element Analysis

For the problems of machining distortion and the low accepted product during milling process of aluminum alloy thin-walled part,this paper starts from the analysis of initial stress state in material preparation process,the change process of residual stress within aluminum alloy pre-stretching plate is researched,and the distribution law of residual stress is indirectly obtained by delamination measurement methods,so the effect of internal residual stress on machining distortion is considered before finite element simulation. Considering the coupling effects of residual stress,dynamic milling force and clamping force on machining distortion,a threedimensional dynamic finite element simulation model is established,and the whole cutting process is simulated from the blank material to finished product,a novel prediction method is proposed,which can availably predict the machining distortion accurately. The machining distortion state of the thin-walled part is achieved at different processing steps,the machining distortion of the thin-walled part is detected with three coordinate measuring machine tools,show that the simulation results are in good agreement with experimental data.

Reinforcement learning method for machining deformation control based on meta-invariant feature space

Precise control of machining deformation is crucial for improving the manufacturing quality of structural aerospace components.In the machining process,different batches of blanks have different residual stress distributions,which pose a significant challenge to machining deformation control.In this study,a reinforcement learning method for machining deformation control based on a meta-invariant feature space was developed.The proposed method uses a reinforcement-learning model to dynamically control the machining process by monitoring the deformation force.Moreover,combined with a meta-invariant feature space,the proposed method learns the internal relationship of the deformation control approaches under different stress distributions to achieve the machining deformation control of different batches of blanks.Finally,the experimental results show that the proposed method achieves better deformation control than the two existing benchmarking methods.

Machining deformation of single-sided component based on finishing allowance optimization

Owing to reliability and high strength-to-weight ratio,large thin-walled components are widely used in the aviation and aerospace industry.Due to the complex features and sequence involved in the machining process of large thin-walled components,machining deformation of component is easy to exceed the specification.In order to address the problem,it is important to retain the appropriate finishing allowance.To find the overall machining deformation,finishing allowance-induced deformation(web finishing allowance,sidewall finishing allowance)and initial residual stress-induced deformation were considered as major factors.Meanwhile,machined surface residual stress-induced deformation,clamping stress-induced deformation,thermal deformation,gravity-induced deformation and inertial force-induced deformation were neglected in the optimization model.Six-peak Gaussian function was introduced to fit the initial residual stress.Based upon the obtained function of initial residual stress,a deformation prediction model between initial residual stress and finishing allowance was established to attain the finishing allowanceinduced deformation.In addition,linear programming optimization model based on the simplex algorithm was developed to optimize the overall machining deformation.Results have concluded that the overall machining deformation reached the minimum value when sidewall finishing allowance and web finishing allowance varied between 1 and 2 mm.Additionally,web finishing allowance-induced deformation and sidewall finishing allowance-induced deformation were1.05 mm and 0.7 mm.Furthermore,the machining deformation decreased to 0.3–0.38 mm with the application of optimized finishing allowance allocation strategy,which made 39–56%reduction of the overall machining deformation compared to that in conventional method.

Finite Element Simulation of Deformation in Machining Large Thin-walled Aluminum Alloy Ring

Based on the finite element method,the model was established to predict the deformation of large thin-walled ring during machining.After the simulation of heat treatment and 3D cutting process,the factors of initial residual stress,clamping operation,cutting loads and thermal stresses were investigated to evaluate the machining deformation.The results showed that the main factor which influenced machining deformation was initial residual stress produced in quenching process.Improving the clamping method could decrease the machining deformation caused by the release of residual stresses.In the process of finish machining,the cutting force and cutting temperature were low which caused little effect on machining deformation.

Stress-Induced Deformation of Thin Copper Substrate in Double-Sided Lapping

Double-sided lapping is an precision machining method capable of obtaining high-precision surface.However,during the lapping process of thin pure copper substrate,the workpiece will be warped due to the influence of residual stress,including the machining stress and initial residual stress,which will deteriorate the flatness of the workpiece and ultimately affect the performance of components.In this study,finite element method(FEM)was adopted to study the effect of residual stress-related on the deformation of pure copper substrate during double-sided lapping.Considering the initial residual stress of the workpiece,the stress caused by the lapping and their distribution characteristics,a prediction model was proposed for simulating workpiece machining deformation in lapping process by measuring the material removal rate of the upper and lower surfaces of the workpiece under the corresponding parameters.The results showed that the primary cause of the warping deformation of the workpiece in the doublesided lapping is the redistribution of initial residual stress caused by uneven material removal on the both surfaces.The finite element simulation results were in good agreement with the experimental results.

High-precision Thickness Setting Models for Titanium Alloy Plate Cold Rolling without Tension

Due to its highly favorable physical and chemical properties,titanium and titanium alloy are widely used in a variety of industries.Because of the low output of a single batch,plate cold rolling without tension is the most common rolling production method for titanium alloy.This method is lack of on-line thickness closed-loop control,with carefully thickness setting models for precision.A set of high-precision thickness setting models are proposed to suit the production method.Because of frequent variations in rolling specification,a model structural for the combination of analytical models and statistical models is adopted to replace the traditional self-learning method.The deformation resistance and friction factor,the primary factors which affect model precision,are considered as the objectives of statistical modeling.Firstly,the coefficient fitting of deformation resistance analytical model based on over-determined equations set is adopted.Additionally,a support vector machine（SVM）is applied to the modeling of the deformation resistance and friction factor.The setting models are applied to a 1450 plate-coiling mill for titanium alloy plate rolling,and then thickness precision is found consistently to be within 3%,exceeding the precision of traditional setting models with a self-learning method based on a large number of stable rolling data.Excellent application performance is obtained.The proposed research provides a set of high-precision thickness setting models which are well adapted to the characteristics of titanium alloy plate cold rolling without tension.