Skip to main content
SpringerLink
Log in

Machining distortion minimization for the manufacturing of aeronautical structure

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The distortion of machined parts is a major concern in the manufacture of aeronautical monolithic structures. We investigated the influence of material removal partition on residual stress in high-strength aluminum alloy parts to minimize machining distortion. In the present study, a methodology of minimizing machining distortion based on an accurate cross-sectional residual stress determination is presented, which can be applied to avoid or minimize part distortions in advance by adapting machining strategies or process conditions. A powerful contour method was used first to measure bulk residual stress within the blank. Next, a finite element model was applied to predict machining distortion based on measured residual stress for analyzing part distortion. Finally, experimental verification was provided by comparing measured distortion and predicted distortion by the finite element analysis. This simulation showed that part distortion is mainly affected by the partition of material removal in T-shaped components. Our results also indicate that distortion can be minimized by optimizing the partition of material removal to ensure a symmetrical distribution of residual stress in the part so that the residual stress-induced bending moment could reach self equilibrium.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

References

  1. Denkena B, Dreier S (2014) New production technologies in aerospace industry. In: Denkena B (ed) Simulation of residual stress related part distortion. Springer, Switzerland, pp 105–113

    Google Scholar 

  2. Lequeu P, Lassince P, Warner T, Raynaud GM (2001) Engineering for the future: weight saving and cost reduction initiatives. Aircr Eng Aerosp Tech 73:147–159

    Article  Google Scholar 

  3. Sim WM (2008) Challenges of residual stress and part distortion in the civil airframe industry. 2nd International Conference on Distortion Engineering, Bremen, Germany

  4. Younger MS, Eckelmeyer HK (2007) Overcoming residual stress and machining distortion in the production of aluminum alloy satellite boxes. Technical Report SAND2007-6811, Sandia National laboratories, USA

  5. Prime MB, Hill MR (2002) Residual stress, stress relief, and inhomogeneity in aluminum plate. Scr Mater 46:77–82

    Article  Google Scholar 

  6. Watton JD (2010) Computational modeling and optimization of bulk residual stress in monolithic aluminum die forgings. 4th Residual Stress Summit, Lake Tahoe, USA

  7. Ball DL, Watton JD (2011) Fatigue life variability in large aluminum forgings with residual stress. 52nd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Denver, Colorado, USA

  8. Robinson JS, Hossain S, Truman CE, Paradowska AM, Hughes DJ, Wimpory RC, Fox ME (2010) Residual stress in 7449 aluminium alloy forgings. Mater Sci Eng A-Struct 527:2603–2612

    Article  Google Scholar 

  9. Brinksmeier E, Cammett JT, Konig W, Leskovar P, Peters J, Tonshoff HK (1982) Residual stress—measurement and causes in machining processes. Ann CIRP 31(2):491–510

    Article  Google Scholar 

  10. Brinksmeier E, Lubben T, Fritsching U, Cui C, Rentsch R, Solter J (2011) Distortion minimization of disks for gear manufacture. Int J Mach Tool Manu 51:331–338

    Article  Google Scholar 

  11. Nervi S, Szabó BA, Young KA (2009) Prediction of distortion of airframe components made from aluminum plates. AIAA J 27:1635–1641

    Article  Google Scholar 

  12. Brinksmeier E, Solter J (2009) Prediction of shape deviations in machining. Ann CIRP 58:507–510

    Article  Google Scholar 

  13. Ma K, Goetz R, Srivatsa SK (2010) Modeling of residual stress and machining distortion in aerospace components. Technical Report AFRL-RX-WP-TP-2010-4148, United States Air Force

  14. Prime MB (2001) Cross-sectional mapping of residual stressed by measuring the surface contour after a cut. J Eng Mater-T ASME 123:162–168

    Article  Google Scholar 

  15. Prime MB, Sebring RJ, Edwards JM, Hughes DJ, Webster PJ (2004) Laser surface contouring and spline data-smoothing for residual stress measurement. Exp Mech 44(2):176–184

    Article  Google Scholar 

  16. Hosseinzadeh F, Toparli MB, Bouchard PJ (2012) Slitting and contour method residual stress measurements in an edge weld beam. J Press Vess Technol 134(1):011402-1–011402-6

    Article  Google Scholar 

  17. Johnson G (2008) Residual stress measurements using the contour method. Dissertation, University of Manchester

  18. Greving DJ, Rybicki EF, Shadley JR (1994) Through-thickness residual-stress evaluations for several industrial thermal spray coatings using a modified layer-removal method. J Therm Spray Technol 3(4):379–388

    Article  Google Scholar 

  19. Trummer VR, Koch D, Witte A, dos Santos JF, de Castro PMST (2013) Methodology for prediction of distortion of workpieces manufactured by high speed machining based on an accurate through-the-thickness residual stress determination. Int J Adv Manuf Technol 68:2271–2281

    Article  Google Scholar 

  20. Prime MB (1999) Residual stress measurement by successive extension of a slot: the crack compliance method. Appl Mech Rev 52(2):75–96

    Article  Google Scholar 

  21. Timoshenko SP, Goodier JN (1970) Theory of elasticity. McGraw-Hill, New York

    MATH  Google Scholar 

  22. Withers PJ, Webster PJ (2001) Neutron and synchrotron x-ray scanning. Strain 27(1):9–33

    Google Scholar 

  23. American Society for Testing and Materials E837–08 (2008) Standard test method for determining residual stresses by the hole-drilling strain-gage method. ASTM International, Pennsylvania

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Zheng Zhang, Liang Li, Yinfei Yang, Ning He & Wei Zhao

Authors
  1. Zheng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Liang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yinfei Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ning He
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wei Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zheng Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, Z., Li, L., Yang, Y. et al. Machining distortion minimization for the manufacturing of aeronautical structure. Int J Adv Manuf Technol 73, 1765–1773 (2014). https://doi.org/10.1007/s00170-014-5994-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-5994-1

Keywords

Search

Navigation