| Civil and Mechanical Engineering |
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| Machining distortion prediction of aerospace monolithic components |
| Yun-bo BI, Qun-lin CHENG, Hui-yue DONG, Ying-lin KE |
| State Key Lab of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China; Shanghai Spaceflight Precision Machinery Research Institute, Shanghai 201600, China |
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Abstract To predict the distortion of aerospace monolithic components, a model is established to simulate the numerical control (NC) milling process using 3D finite element method (FEM). In this model, the cutting layer is simplified firstly. Then, the models of cutting force and cutting temperature are established to gain the cutting loads, which are applied to the mesh model of the part. Finally, a prototype of machining simulation environment is developed to simulate the milling process of a spar. Key factors influencing the distortion, such as initial residual stress, cutting loads, fixture layout, cutting sequence, and tool path are considered all together. The total distortion of the spar is predicted and an experiment is conducted to validate the numerical results. It is found that the maximum discrepancy between the simulation results and experiment values is 19.0%.
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Received: 23 May 2008
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