Research On Milling Deformation Model And Residual Stress Of Alulninum Alloy Thin-walled Workpieces

The machining distortion is one of the neck problems during the manufacture of the aero integrated-structure parts. Residual stress is the main factor of leading to machining distortion. The machining distortion affects the production schedule and quality; the stress may shorten the service life. So it is important to research on the stress and milling deformation for aluminum alloy thin-walled workpieces.Firstly, research background and status at home and abroad of this topic were introduced, and the research methods and contents were discussed in this paper.Secondly, based on the elastic theory, the deformation of aluminum alloy plate with two-way residual stress after machining was studied. The deformation prediction model containing the bend deformation curvature was built. The bend deformation deflection value of component before and after milling, was considered as evaluation parameter of milling deformation, and the veracity of deformation model of the whole layer’s milling parts was verified.Thirdly, a system for analyzing residual stress of Aluminum alloy plate was developed, which was based on MSC.Patran platform and programmed by the secondary development language and model log files. It realized parameterization and enhanced analytical efficiency greatly. It could provide residual stress to aluminum alloy frame structures.Fourthly, the machining process of frame structures was simulated by using MSC.Marc software. The change of residual stress during machining and the milling deformation of the frame structures caused by different residual stress and different milling rate were deduced. The changing parameters of the bend deformation curvature of component before and after milling were deduced by regression analysis. Then the complete deformation model was studied.Lastly, the source of error was analyzed by comparing the simulation calculation model with simulation experiment. Influence on milling deformation from milling rate and frame slot number and the rationality of milling deformation were verified.