Owing to reliability and high strength-to-weight ratio,large thin-walled components are widely used in the aviation and aerospace industry.Due to the complex features and sequence involved in the machining process of ...Owing to reliability and high strength-to-weight ratio,large thin-walled components are widely used in the aviation and aerospace industry.Due to the complex features and sequence involved in the machining process of large thin-walled components,machining deformation of component is easy to exceed the specification.In order to address the problem,it is important to retain the appropriate finishing allowance.To find the overall machining deformation,finishing allowance-induced deformation(web finishing allowance,sidewall finishing allowance)and initial residual stress-induced deformation were considered as major factors.Meanwhile,machined surface residual stress-induced deformation,clamping stress-induced deformation,thermal deformation,gravity-induced deformation and inertial force-induced deformation were neglected in the optimization model.Six-peak Gaussian function was introduced to fit the initial residual stress.Based upon the obtained function of initial residual stress,a deformation prediction model between initial residual stress and finishing allowance was established to attain the finishing allowanceinduced deformation.In addition,linear programming optimization model based on the simplex algorithm was developed to optimize the overall machining deformation.Results have concluded that the overall machining deformation reached the minimum value when sidewall finishing allowance and web finishing allowance varied between 1 and 2 mm.Additionally,web finishing allowance-induced deformation and sidewall finishing allowance-induced deformation were1.05 mm and 0.7 mm.Furthermore,the machining deformation decreased to 0.3–0.38 mm with the application of optimized finishing allowance allocation strategy,which made 39–56%reduction of the overall machining deformation compared to that in conventional method.展开更多
Pure iron is one of the difficult-to-machine materials due to its large chip deformation,adhesion,work-hardening,and built-up edges formation during machining.This leads to a large workpiece deformation and challenge ...Pure iron is one of the difficult-to-machine materials due to its large chip deformation,adhesion,work-hardening,and built-up edges formation during machining.This leads to a large workpiece deformation and challenge to meet the required technical indicators.Therefore,under varying the grain size of pure iron,the influence of cutting speed,feed,and depth of cut on the cutting force,heat generation,and machining residual stresses were explored in the turning process to improve the machinability without compromising the mechanical properties of the material.The experimental findings have depicted that the influence of grain size on cutting force in the precision turning process is not apparent.However,the cutting temperature and residual stress of machining fine-grain iron were much smaller than the coarse grain at all levels of cutting parameters.展开更多
In the machining process of aircraft monolithic parts,the initial residual stress redistribution and structural stiffness evolution often lead to unexpected distortions.On the other hand,the stress redistribution and ...In the machining process of aircraft monolithic parts,the initial residual stress redistribution and structural stiffness evolution often lead to unexpected distortions.On the other hand,the stress redistribution and stiffness reduction during the machining process depend on the material removal sequence.The essence of the stress redistribution is releasing the initial elastic strain energy.In the present study,the influence of the material removal sequence on the energy release is studied.Moreover,a novel optimization method is proposed for the material removal sequence.In order to evaluate the performance of the proposed method,the mechanism of the machining distortion is firstly analyzed based on the energy principle.Then a calculative model for the machining distortion of long beam parts is established accordingly.Moreover,an energy parameter related to the bending distortion and the procedure of the material removal sequence optimization is defined.Finally,the bending distortion analysis and material removal sequence optimization are performed on a long beam with a Z-shaped cross-section.Furthermore,simulation and experiments are carried out.The obtained results indicate that the optimized sequence results in a low distortion fluctuation and decreases the bending distortion.展开更多
Thin-walled long stringer made of aluminum alloy 7050-T7451 is prone to deformation during transportation,so a research of residual stress relaxation was launched in this paper.The transport resonance stress of long s...Thin-walled long stringer made of aluminum alloy 7050-T7451 is prone to deformation during transportation,so a research of residual stress relaxation was launched in this paper.The transport resonance stress of long stringer was analyzed based on the power spectral density of road transport acceleration.The residual stress relaxation experiment of aluminum alloy 7050-T7451 under different equivalent stress levels was designed and carried out.According to the amount of residual stress relaxation in the experiment,an analytical model was established with the equivalent stress level coefficient.The deflection range of long stringer was evaluated under different damping ratios.The results show that when the equivalent stress exceeds 0.8σ0.2,the residual stress relaxation of the thin-walled samples occurs.The residual stress relaxation increases linearly with the equivalent stress,which is logarithmically related to the loading cycle.The deformation caused by residual stress relaxation of the long stringer is proportional to the square of the length and the bending moment caused by stress rebalance,and inversely proportional to the moment of inertia of the structure.As the damping ratio decreases from 0.03 to 0.01,the total deflection of the long stringer increases from 0 to above 1.55 mm.展开更多
基金co-supported by the National Natural Science Foundation of China(No.51405226)Postgraduate Research&Practice Innovation Program of Jiangsu Province of China(No.KYCX19_0165)。
文摘Owing to reliability and high strength-to-weight ratio,large thin-walled components are widely used in the aviation and aerospace industry.Due to the complex features and sequence involved in the machining process of large thin-walled components,machining deformation of component is easy to exceed the specification.In order to address the problem,it is important to retain the appropriate finishing allowance.To find the overall machining deformation,finishing allowance-induced deformation(web finishing allowance,sidewall finishing allowance)and initial residual stress-induced deformation were considered as major factors.Meanwhile,machined surface residual stress-induced deformation,clamping stress-induced deformation,thermal deformation,gravity-induced deformation and inertial force-induced deformation were neglected in the optimization model.Six-peak Gaussian function was introduced to fit the initial residual stress.Based upon the obtained function of initial residual stress,a deformation prediction model between initial residual stress and finishing allowance was established to attain the finishing allowanceinduced deformation.In addition,linear programming optimization model based on the simplex algorithm was developed to optimize the overall machining deformation.Results have concluded that the overall machining deformation reached the minimum value when sidewall finishing allowance and web finishing allowance varied between 1 and 2 mm.Additionally,web finishing allowance-induced deformation and sidewall finishing allowance-induced deformation were1.05 mm and 0.7 mm.Furthermore,the machining deformation decreased to 0.3–0.38 mm with the application of optimized finishing allowance allocation strategy,which made 39–56%reduction of the overall machining deformation compared to that in conventional method.
基金National Defense Foundation Pre-Research Science Challenge Project(Grant No.JCKY2016212A506-0107)Development Funds of China Academy of Engineering Physics(Grant No.2015B0203029).
文摘Pure iron is one of the difficult-to-machine materials due to its large chip deformation,adhesion,work-hardening,and built-up edges formation during machining.This leads to a large workpiece deformation and challenge to meet the required technical indicators.Therefore,under varying the grain size of pure iron,the influence of cutting speed,feed,and depth of cut on the cutting force,heat generation,and machining residual stresses were explored in the turning process to improve the machinability without compromising the mechanical properties of the material.The experimental findings have depicted that the influence of grain size on cutting force in the precision turning process is not apparent.However,the cutting temperature and residual stress of machining fine-grain iron were much smaller than the coarse grain at all levels of cutting parameters.
基金the National Natural Science Foundation of China(No.51405226)。
文摘In the machining process of aircraft monolithic parts,the initial residual stress redistribution and structural stiffness evolution often lead to unexpected distortions.On the other hand,the stress redistribution and stiffness reduction during the machining process depend on the material removal sequence.The essence of the stress redistribution is releasing the initial elastic strain energy.In the present study,the influence of the material removal sequence on the energy release is studied.Moreover,a novel optimization method is proposed for the material removal sequence.In order to evaluate the performance of the proposed method,the mechanism of the machining distortion is firstly analyzed based on the energy principle.Then a calculative model for the machining distortion of long beam parts is established accordingly.Moreover,an energy parameter related to the bending distortion and the procedure of the material removal sequence optimization is defined.Finally,the bending distortion analysis and material removal sequence optimization are performed on a long beam with a Z-shaped cross-section.Furthermore,simulation and experiments are carried out.The obtained results indicate that the optimized sequence results in a low distortion fluctuation and decreases the bending distortion.
基金Supported by National Natural Science Foundation of China(Grant No.51405226).
文摘Thin-walled long stringer made of aluminum alloy 7050-T7451 is prone to deformation during transportation,so a research of residual stress relaxation was launched in this paper.The transport resonance stress of long stringer was analyzed based on the power spectral density of road transport acceleration.The residual stress relaxation experiment of aluminum alloy 7050-T7451 under different equivalent stress levels was designed and carried out.According to the amount of residual stress relaxation in the experiment,an analytical model was established with the equivalent stress level coefficient.The deflection range of long stringer was evaluated under different damping ratios.The results show that when the equivalent stress exceeds 0.8σ0.2,the residual stress relaxation of the thin-walled samples occurs.The residual stress relaxation increases linearly with the equivalent stress,which is logarithmically related to the loading cycle.The deformation caused by residual stress relaxation of the long stringer is proportional to the square of the length and the bending moment caused by stress rebalance,and inversely proportional to the moment of inertia of the structure.As the damping ratio decreases from 0.03 to 0.01,the total deflection of the long stringer increases from 0 to above 1.55 mm.
