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Keywords = aircraft monolithic part

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23 pages, 8829 KiB  
Article
A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys
by Magdalena Zawada-Michałowska, Paweł Pieśko, Jerzy Józwik, Stanisław Legutko and Leon Kukiełka
Materials 2021, 14(23), 7242; https://doi.org/10.3390/ma14237242 - 27 Nov 2021
Cited by 16 | Viewed by 2516
Abstract
In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural [...] Read more.
In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified. Full article
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16 pages, 8310 KiB  
Article
Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle
by Longxin Fan, Hui Tian, Liang Li, Yinfei Yang, Nenggan Zhou and Ning He
Metals 2020, 10(12), 1586; https://doi.org/10.3390/met10121586 - 27 Nov 2020
Cited by 14 | Viewed by 3344
Abstract
Machining distortion is a recurring problem in the machining of monolithic aircraft parts. This paper aims to study the machining distortion minimization of monolithic aircraft parts. Firstly, the energy principle of machining distortion was analyzed. Then, a rapid prediction model of the final [...] Read more.
Machining distortion is a recurring problem in the machining of monolithic aircraft parts. This paper aims to study the machining distortion minimization of monolithic aircraft parts. Firstly, the energy principle of machining distortion was analyzed. Then, a rapid prediction model of the final part distortion for beam parts was proposed based on the equivalent stress, and the initial bending strain energy contained in the final part was used to characterize the bending distortion risk of the final part. Numerical simulation and milling experiments verified the effectiveness of the proposed prediction model. The relative error between the experimental and calculated results does not exceed 26.5%. Finally, the influence of initial residual stress fluctuation, part geometry and the part location on part distortion was analyzed from the energy point of view. The obtained results indicated that the expected final part distortion can be minimized by adjusting these three factors. Full article
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