Optimization of support location in mirror-milling of aircraft skins

Abstract

As a new technology of reducing thickness of an aircraft skin, the mirror-milling system is widely used. The objective of this study is to optimize the support location in mirror-milling of aircraft skins. The study analyzes the machining mechanisms of mirror-milling system and establishes a theoretical model to predict the milling forces. In addition, it develops a finite element model to simulate workpiece deformation so as to predict workpiece profiles in mirror-milling system. The results of the study show that with the optimized support location, the profile error of the workpiece is reduced by 73.5%, whereas machining efficiency is increased.

Research on the Dynamic Flexible Support Machining Method for Propeller Blades

“…Bao makes the stiffness distribution of the workpiece in the machining process have the same trend with the change of cutting force to optimize the support position of the multi-point support machining. The research results show that after optimizing the support position, the contour error of the part is signi cantly reduced [18,19]. Hao established an integrated stiffness model of the workpiece and the support mechanism for the mirror-image support equipment and optimized the distribution of the integrated stiffness on the surface of the workpiece by increasing the redundancy drive.…”

Vacuum preloading hydrostatic support technology for mirror milling of thin-walled parts

“…Wang et al [14] conducted a stability analysis of mirror milling to reveal the stability change and destabilization mechanism of the mirror milling process. Bao et al [15]reduced the machining contour error by optimizing the supporting head support position. In terms of processing paths and tool compensation, Zhang et al [16] proposed a method of tool path optimization to make the rotary axis motion smoother, shorten the machining time and improve the machining quality.…”

Efficient prediction of milling distortion using inversely-identified inherent strains

“…Considering the machining induced surface stresses, Wan et al [5] presented an analytical simulation model combined with the layer removal method. Bao et al [6] develops a finite element model to optimize the support location in mirror-milling, and the results show that the profile error is reduced by 73.5%, whereas machining efficiency is increased. Based on the explicit calculation of grain size growth and phase transformation, Pan et al [7] developed a microstructure-sensitive Johnson-Cook model for the distortion prediction of Ti-6Al-4V.…”