Abstract
Main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component are investigated by finite element simulation and experiment. Based on an analysis of milling process characters, finite element models of machining distortion are developed. Considering the action of initial residual stress, finite element simulation and analysis of machining distortion for aluminum alloy aircraft monolithic component are performed. Initial residual stress, cutting loads, and coupling action of these two effect factors are taken into account, respectively, to perform finite element simulations of machining distortion for titanium alloy aircraft monolithic component. The finite element simulation results are compared with experiment results and found to be in good agreement, indicating the validation of the proposed finite element models. The research results show that the initial residual stress in the blank is the main effect element of machining distortion for aluminum alloy aircraft monolithic component, while cutting loads (including cutting force and temperature) are the main effect element of machining distortion for titanium alloy aircraft monolithic component. To decrease machining distortion of aluminum alloy aircraft monolithic component, the initial residual stress in the blank must be controlled first. Similarly, to decrease machining distortion of titanium alloy aircraft monolithic component, the cutting loads must be controlled first.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Megson THG (2012) Aircraft structures for engineering students. Leeds University, UK
Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: a review. Int J Mach Tools Manuf 51(3):250–280
Izamshah R, Mo JPT, Ding S (2011) Hybrid deflection prediction on machining thin-wall monolithic aerospace components. J Eng Manuf 203(9):687–698
He N, Wang ZG, Jiang CY, Zhang B (2003) Finite element method analysis and control stratagem for machining deformation of thin-walled components. J Mater Process Technol 139(1–3):332–336
Yu W, Wang XW (2007) Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts. Int J Adv Manuf Tech 33(3–4):260–265
Ratchev S, Liu S, Huang W, Becker AA (2006) An advanced FEA based force induced error compensation strategy in milling. Int J Mach Tools Manuf 46:542–551
Ratchev S, Liu S, Becker A (2005) Error compensation strategy in milling flexible thin-wall parts. J Mater Process Technol 23(3):673–681
Wan M, Zhang WH, Qiu KP (2005) Numerical prediction of static form errors in peripheral milling of thin-walled workpieces with irregular meshes. J Manuf Sci Eng 127:13–22
Herranz S, Campa FJ, Rivero A (2005) The milling of airframe components with low rigidity: a general approach to avoid static and dynamic problems. J Eng Manuf 219(11):789–801
Jitender K, Rai PX (2008) Finite element method based machining simulation environment for analyzing part errors induced during milling of thin-walled components. Int J Mach Tools Manuf 48:629–643
MSC.Software Corporation (2005) Theory and user information. MSC.Marc Version
Yang Y, Wang YL, Li CH (2011) Study on machining distortion of titanium alloy aircraft monolithic component by finite element method and experiment. Adv Sci Lett 4(5):1–5
Guo H, Zuo DW, Wu HB, Xua F, Ton GQ (2009) Prediction on milling distortion for aero-multi-frame parts. Mater Sci Eng 499(2):230–233
Liu G (2009) Study on deformation of titanium thin-walled part in milling process. J Mater Process Technol 209:2788–2793
Zhang YD, Zhang HW (2009) Finite element simulation of machining deformation for aeronautical mono lithic component. J Beijing Univ Aeronaut Astronaut 35(2):188–192
Bi YB, Cheng QL (2009) Machining distortion prediction of aerospace monolithic components. J Zhejiang Univ Sci A 10(5):661–668
Dong HY, Ke YL (2006) Study on machining deformation of aircraft monolithic component by FEM and experiment. Chin J Aeronaut 19(3):247–254
Wang SH (2005) Study on initial residual stresses and their effects on milling distortion for thick aero-aluminum-alloy plate. Nanjing University of Aeronautics and Astronautics, Dissertation
Shin SH (1995) Prediction of the dimensional instability resulting from machining of residually stressed components. Texas Tech University, Dissertation
Bi YB, Cheng QL (2008) Distortion prediction of aerospace monolithic components due to milling process. Key Eng Mater 392–394:841–847
Yang Y (2007) Study on prediction of distortion due to milling process for aerospace monolithic component of titanium alloy. Zhejiang University, Dissertation
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Yang, Y., Li, M. & Li, K.R. Comparison and analysis of main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component. Int J Adv Manuf Technol 70, 1803–1811 (2014). https://doi.org/10.1007/s00170-013-5431-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5431-x