Machining-induced distortion of large monolithic parts with thin walled structures creates problems in aircraft manufacturing industry. Typical monolithic beams of airframe are machined by NC machine and machining distortions are recorded. Thin walled structures are prone to distortions and dimensional instabilities due to internal stresses; therefore, stress-relieved vibration method is applied to reduce the internal stresses in blank material and results in better machining performance and dimension stability. But vibration stress-relief method doesn’t work always due to unknown reasons. Machining simulations in ANSYS are performed to predict the residual stress-induced machining distortion and simulation result is compared with the machining measurements to validate the simulation process. Cutting simulations have been executed by the element deactivation technique after developing the initial residual stresses via sequential coupled field analysis. The possibility of residual stress being relieved more reasonably and less distortion by optimized machining sequence through simulation is discussed.

MBD (Model Based Definition) technology is a digital method of product definition which combines all information required for manufacturing into the 3D design model including annotation, processing description, attributes and management information. This advancement is a not only a change in media used in the design, manufacturing, inspection and management cycles of the product but also a disruptive reform in engineering-thinking. MBD technology defines a product completely without traditional engineering drawing which is challenging the engineering graphics education. Though MBD technology has not been fully tested or fully developed in all field, change and revolution in relative engineering education must be taken into consideration simultaneously. By comparing the traditional 2D and 3D representation methods with the MBD technology including geometric and non-geometric information of product, some suggestions are presented in contemporary engineering graphics education.