Machining deformation analysis of aircraft monolithic components based on the energy method

• DOI: 10.1007/s00170-021-08531-z
• Publication Date: 2022-01-16T00:03:06Z
• Authors: Xiaoming Huang; Xiaoliang Liu; Jiaxing Li; Yongbin Chen; Dechen Wei; Guichu Ding
• Keywords: Blank; Stiffening

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 case 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 theoretical model. Then, FEM simulation is carried out to analyze the influence of stiffening ribs on machining deformation utilizing the semi-analytical model of equivalent bending stiffness. 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.