Recent progress in flexible supporting technology for aerospace thin-walled parts: A review

Bao, Yan; Wang, Bin; He, Zengxu; Kang, Renke; Guo, Jun

doi:10.1016/j.cja.2021.01.026

“…As the prime die moved, the contact area between the dies and the workpiece rapidly expanded, leading to a significant amplification in the degree of workpiece deformation. (2) In the middle phase of the forging stage, the force growth rate decelerated, potentially due to the stabilization of the contact area between the dies and the workpiece. (3) In the final phase of the forging stage, there was a sharp surge in the force.…”

Section: Forging Forcementioning

confidence: 99%

Analyzing Forged Quality of Thin-Walled A-286 Superalloy Tube under Multi-Stage Cold Forging Processes

Tao

¹

,

Feng

²

,

Jiang

³

et al. 2023

Materials

3

0

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Cold forging is suitable for manufacturing thin-walled tubes; however, a poorly planned forging process results in serious quality problems. This paper aims to determine an appropriate cold forging process for thin-walled A286 superalloy tube with ideal forming quality. We analyzed the effects of the two forging processes with reverse forging sequences on forming defects and hardness distribution in the thin-walled tubes via finite element simulation. The methods of optical microscope, micro-hardness, scanning electron microscope, and electron-backscattered diffraction were used to validate the tube forming quality. The simulation results revealed that the Type-I process was an appropriate forging process for meeting the quality requirements. For the Type-I process, an underfilling defect was observed at the bottom of the rod section of the tube. The stress concentration in the head section was lower than that in the Type-II process, potentially reducing the probability of crack initiation. Compared to the rod section, the head section may exhibit higher hardness magnitudes due to the greater strain distribution. The experimental results confirmed the feasibility of the Type-I process. The increased hardness in the head section may be primarily attributed to the more intense plastic deformation applied to the material in this section by the Type-I process.

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“…For example, wax 12 or ice 13 are filled in the deep and narrow space to provide extra support as they could easily be removed by the cutting tool. Recent overviews related to fixtures can be found in 14 , 15 . Additionally, high-speed machining (HSM) is popularly applied for the machining of aircraft structural components characterized by deep and thin-walled structures.…”

Section: Introductionmentioning

confidence: 99%

Numerical evaluation of cutting strategies for thin-walled parts

Lassila,

Svensson,

Wang

et al. 2024

Sci Rep

2

0

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Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

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“…For example, wax [12] or ice [13] are filled in the deep and narrow space to provide extra support as they could easily be removed by the cutting tool. Recent overviews related to fixtures can be found in [14,15].…”

Section: Introductionmentioning

confidence: 99%

Numerical evaluation of cutting strategies for thin-walled parts

Lassila¹,

Svensson

²

,

Wang³

et al. 2023

Preprint

0

View full text Add to dashboard Cite

Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

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Recent progress in flexible supporting technology for aerospace thin-walled parts: A review

Cited by 47 publications

References 49 publications

Analyzing Forged Quality of Thin-Walled A-286 Superalloy Tube under Multi-Stage Cold Forging Processes

Analyzing Forged Quality of Thin-Walled A-286 Superalloy Tube under Multi-Stage Cold Forging Processes

Numerical evaluation of cutting strategies for thin-walled parts

Numerical evaluation of cutting strategies for thin-walled parts

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