Aviation Thin Wall Milling Distortion Analysis And Experimental Study

The distortion of Aeronautical thin-wall components due to CNC machining is the key of influencing machining precision and quality in aviation manufacturing technologies, and this problem seriously hinder the development of the aviation industry. So, it has great academic and engineering value for the prediction and improvement of Aeronautical thin-wall components machining distortion. In view of the complex feature of this problem, a method combined experiments with as well as computer analysis is adopted in this dissertation.On the metal cutting principle, this paper analyses thin-wall component machining errors mechanism for aviation aluminum-alloy material 7050-7451. Milling experiment by means of regression-orthogonal method with four factors is designed to confirm associated parameters of cutting force model. A useful milling force model is founded based on the cutting-force characteristics in end milling. The loading method and process was presented by studying machine deformation of the thin-wall components in end milling. The ABAQUS FEM codes for the founded finite element model and related experiments were used to analyze the machining deformation rules of typical thin-wall components. Same valuable conclusions were gained and it could provides good references for improving productivity and the further study of controlling machining distortion of thin-wall components.Based on academic analyses and Finite Element Simulation, in order to validate the availability of milling force model and Finite Element simulation results, Many machining experiments are arranged using different cutting parameters groups for typical thin-wall components with different geometrical shape and dimension.