An analytical machining deformation model of asymmetric structural thin-walled components

The deformation prediction and control of thin-walled components are receiving increasing attention. Residual stress is an important factor affecting the deformation of workpieces. A deformation prediction model considering machining residual stress is proposed based on the theory of thin plate bending. The introduced machining residual stress was calculated using contour method and XRD diffraction method. The variation of residual stress after coupling was derived using the layer shifting method, and the influence of neutral layer position variation on residual stress redistribution was analyzed. The accuracy of the model was verified through corresponding experiments and finite element simulations, with relative errors of 12.1 % and 50.2 %, respectively. In addition, the deformation of rectangular and complex shaped thin-walled parts was compared through finite element simulation, which extended the application scope of thin plate bending theory. In addition, ten material removal processes were simulated and calculated using the life and death unit method, and the optimal processing technology was confirmed. Corresponding experiments were conducted to verify the results, with a maximum relative error of 17.6 %. In addition, the residual stress was reduced by multiple deep cooling treatments and composite ultrasonic vibration aging methods, with a maximum residual stress reduction rate of 25.1 %. Finally, the overall deformation of the workpiece was comprehensively characterized, and the flatness of the four different surfaces was reduced to 22 μm, 23 μm, 26 μm, and 21 μm respectively through three deep cooling treatments and ultrasonic vibration.