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首页> 外文期刊>International Journal of Material Forming: Official Journal of the European Scientific Association for Material Forming - ESAFORM >Prediction of machining quality due to the initial residual stress redistribution of aerospace structural parts made of low-density aluminium alloy rolled plates
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Prediction of machining quality due to the initial residual stress redistribution of aerospace structural parts made of low-density aluminium alloy rolled plates

机译：由低密度铝合金压延板制成的航空结构部件的初始残余应力再分布会预测加工质量

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摘要

During the machining of thick, large and complex aluminium parts, the redistribution of initial residual stresses is the main reason for machining errors such as dimensional variations and the post-machining distortions. These errors can lead to the rejection of the parts or to additional conforming operations increasing production costs. It is therefore a requirement to predict potential geometrical and dimensional errors resulting from a given machining process plan and in taking into consideration the redistribution of the residual stresses. A specific finite element tool which allows to predict the behaviour of the work-piece during machining due to its changing geometry and to fixture-workpiece contacts has been developed. This numerical tool uses a material removal approach which enables to simulate the machining of parts with complex geometries. In order to deal with industrial problems this numerical tool has been developed for parallel computing, allowing the study of parts with large dimensions. In this paper, the approach developed to predict the machining quality is presented. First, the layer removal method used to determine the initial residual stress profiles of an AIRWARE (R) 2050-T84 alloy rolled plate is introduced. Experimental results obtained are analysed and the same layer removal method is simulated to validate the residual stress profiles and to test the accuracy of the developed numerical tool. The machining of a part taken from this rolled plate is then performed (experimentally and numerically). The machining quality obtained is compared, showing a good agreement, thus validating the numerical tool and the developed approach. This study also demonstrates the importance of taking into account the mechanical behaviour of the workpiece due to the redistribution of the initial residual stresses during machining when defining a machining process plan.
机译：在加工厚，大型和复杂的铝制零件时，初始残余应力的重新分布是造成加工误差（例如尺寸变化和加工后变形）的主要原因。这些错误可能导致零件报废或进行其他合格操作，从而增加生产成本。因此，需要预测由于给定的加工工艺计划而导致的潜在几何和尺寸误差，并考虑残余应力的重新分布。已经开发了一种特殊的有限元工具，由于其几何形状的变化以及夹具与工件的接触，可以预测工件在加工过程中的行为。该数字工具使用一种材料去除方法，可以模拟具有复杂几何形状的零件的加工。为了解决工业问题，已经开发了该数值工具用于并行计算，从而允许研究大尺寸零件。在本文中，提出了预测加工质量的方法。首先，介绍了用于确定AIRWARE 2050-T84合金轧制板的初始残余应力分布的层去除方法。分析获得的实验结果，并模拟相同的层去除方法，以验证残余应力分布并测试开发的数值工具的准确性。然后（从实验和数值上）对从该轧制板上获得的零件进行机加工。比较获得的加工质量，显示出良好的一致性，从而验证了数值工具和开发的方法。这项研究还表明，在定义加工工艺计划时，考虑到由于加工过程中初始残余应力的重新分布而引起的工件机械性能的重要性。

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