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Metals 2016, 6(4), 80; doi:10.3390/met6040080

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

State Key Laboratory of Virtual Reality Technology and Systems, School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing 100191, China
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Academic Editor: Nong Gao
Received: 25 February 2016 / Revised: 28 March 2016 / Accepted: 29 March 2016 / Published: 7 April 2016
(This article belongs to the Special Issue Aluminum Alloys)
View Full-Text   |   Download PDF [4959 KB, uploaded 7 April 2016]   |  

Abstract

The deformation of aeronautical monolithic components due to CNC machining is a bottle-neck issue in the aviation industry. The residual stress releases and redistributes in the process of material removal, and the distortion of the monolithic component is generated. The traditional one-side machining method will produce oversize deformation. Based on the three-stage CNC machining method, the quasi-symmetric machining method is developed in this study to reduce deformation by symmetry material removal using the M-symmetry distribution law of residual stress. The mechanism of milling deformation due to residual stress is investigated. A deformation experiment was conducted using traditional one-side machining method and quasi-symmetric machining method to compare with finite element method (FEM). The deformation parameters are validated by comparative results. Most of the errors are within 10%. The reason for these errors is determined to improve the reliability of the method. Moreover, the maximum deformation value of using quasi-symmetric machining method is within 20% of that of using the traditional one-side machining method. This result shows the quasi-symmetric machining method is effective in reducing deformation caused by residual stress. Thus, this research introduces an effective method for reducing the deformation of monolithic thin-walled components in the CNC milling process. View Full-Text
Keywords: thin-walled component; residual stress; deformation; CNC machining thin-walled component; residual stress; deformation; CNC machining
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MDPI and ACS Style

Wu, Q.; Li, D.-P.; Zhang, Y.-D. Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method. Metals 2016, 6, 80.

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