Analysis and Control of Machining Distortion for Aircraft Monolithic Component Aided by Computer

Machining distortion of monolithic component is one of the most striking problems that aircraft manufacturing has to face up to. A physics-based material removing process simulation in computer is approached to analyze and control machining distortion. The actual material removing process is simplified and modeled with equivalent chip of uniform thickness. With a single tool-tooth milling process simulation, the machining loads during material removing process are obtained and applied. Restart-calculation is adopted to complete the whole simulation of machining process. The machining distortion law is analyzed and has a good agreement with the experiment result. The cutting parameters and process optimization schemes are put forward to control the machining distortion of aircraft monolithic component. With the help of computer analysis, lengthy and expensive trial and error experiment process can be avoided.