Study On Flexible Tooling System For Aircraft Large-scale Thin-wall Workpiece

To solve problems in aircraft manufacturing, flexible tooling system with"Forming-Machining"process is presented, and research on key technologies in application of flexible tooling system is conducted.Wireless communication technology used in flexible tooling system is researched, and wireless communication platform based on nRF2401A and DSP56F807 is presented. Experiment is designed to check reliability of wireless communication and a resend and check method is developed to prevent data packages from missing.Pointwise degree of freedom is defined on aircraft large-scale thin-wall workpiece during its machining process where traditional six-point location principle is not suitable, and base on which adaptive multi-point location method used for this kind of workpieces is described. Further more, multi-point location/support algorithm is developed to solve positions of location/support spheres of flexible tooling system to construct envelope surface of workpiece and avoid machine tool interference.Self-generation of operation mode optimization is presented referring to self-generation principle. According to information of workpiece and machining process, topological layout and density of location/support array evolve adaptively based on finite element analysis and genetic algorithm to achieve overall optimization, which avoids problems caused by traditional adjusting methods.Bionical dynamic optimization of operation mode is presented. This method adjusts flexible tooling system operation mode according to specified cutting path in way that root system of a plant develops. Experimental results show that support distribution can be optimized to make best used of system resource. Test data of sample workpiece show that flexible tooling system meets the requirements of aircraft large-scale thin-wall workpiece machining with machining accuracy enhanced and manufacturing cycle shortened.