Geometric distortion analysis using a combination of the contour method and machining simulation

Werke, Mats; Wretland, Anders; Ottosson, Peter; Holmberg, Jonas; Machens, Michael; Semere, Daniel

doi:10.1016/j.procir.2018.03.213

Cited by 13 publications

(4 citation statements)

References 6 publications

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“…In this paper, the Contour Method [3] [4], which is an accurate method that overcomes these limitations has been used. The method has been validated by a combined experimental and computational analysis as reported in an earlier work by Werke et al in [5]. This paper is based on these findings.…”

Section: Related Workmentioning

confidence: 62%

“…To overcome this problem an iterative procedure with remapping of the out of plane stresses on the work piece with subsequent spring back calculations was performed. The procedure was repeated until the out of plane stresses reached its original level and resulted in a more correct 3-dimensional stress state [5].…”

Section: Figure 7 Fe-models Of the Sectioned Workpieces With Applied mentioning

confidence: 99%

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Machining Distortion Analysis of Aerospace Components using the Contour Method

Werke¹,

Hossain²,

Semere³

et al. 2019

Linköping Electronic Conference Proceedings

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During machining the accumulated residual bulk stresses induced by previous shape forming process steps, such as forging, casting or additive manufacturing and subsequent heat treatment will be released. This may cause undesirable geometric distortions of the final component and thereby high rejection rates and costs. This problem can be reduced by adjusting process-and design parameters. This paper presents a methodology for minimizing machining distortions. The methodology is based on a combination of procedures for prediction of machining distortions, using the Contour method and procedures for adjustment of machining distortions. Practical experiences are discussed and demonstrated using an aerospace component. The methodology should be executed in close cooperation between several actors in the value chain and best results may be achieved by combining several concepts for adjustment of machining distortions. Further research in conjunction with the Contour method, adaptive fixturing and toolpath adjustment is recommended.

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Section: Related Workmentioning

confidence: 62%

Section: Figure 7 Fe-models Of the Sectioned Workpieces With Applied mentioning

confidence: 99%

Machining Distortion Analysis of Aerospace Components using the Contour Method

Werke¹,

Hossain²,

Semere³

et al. 2019

Linköping Electronic Conference Proceedings

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“…Limitations such as excessive mechanical and/or thermal loads are the most obvious ones as shown in the review of Ezugwu et al [4]. More subtle reasons, like the release of internal stresses, and, to some degree, the introduction of new stresses, that will cause the part to warp and distort, bring additional justification to the use of multiple steps during removal of the allowance [5]. In practice, these steps are effectively divided into two types of operations, commonly referred to as roughing and finishing.…”

Section: Introduction 1background and Objectivementioning

confidence: 99%

Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

Holmberg¹,

Wretland

Berglund³

et al. 2021

JMMP

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The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm.

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“…With the rapid development of modern aviation industry, more and more aircraft monolithic components are applied in the big aircraft and fighter such as wing, girder and bulkhead in fuselage [1,2]. They have the advantage of lightening the weight of the airplane.…”

Section: Introductionmentioning

confidence: 99%

Machining Deformation Analysis of Aircraft Monolithic Components based on the Energy Method

Huang

Liu

et al. 2021

Preprint

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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.

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Geometric distortion analysis using a combination of the contour method and machining simulation

Cited by 13 publications

References 6 publications

Machining Distortion Analysis of Aerospace Components using the Contour Method

Machining Distortion Analysis of Aerospace Components using the Contour Method

Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

Machining Deformation Analysis of Aircraft Monolithic Components based on the Energy Method

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