| Aero-aluminum alloy beam is one kind of integrated structure parts using in the plane balance wing. With the development of aerospace and nation defense, requirement of this widespread used aluminum integrated structure parts is getting tougher and tougher. The main problem is on the machining cost, machining time and the parts quality. The main characteristics of integrated structure parts is that the size is big,wall is thin and machining requirement is high. The main problem is that the distortion is big after machining. The distortion not only affects efficiency, but also reduces the machined quality. Consequently, research on the distortion of integrated structure parts is meaningful.This article studies on the machinability and distortion of Al2024-T351 by experiment and finite element analysis method. According to the manufacturing reality, the milling force, milling temperature, surface roughness and residual stress are studied. Moreover, cutting force coefficients are used to evaluate the effect of cutting parameters. Milling temperature and surface roughness are analyzed by iso-surface and contours. The two analyzing method is useful for parameters optimization. The machined residual stress distribution is studied by The Third Wave Advantage software package.The main reason of distortion is initial stress relief. As a result, mathematic method and simulation are used to study on the distortion mechanism by setting a simple two-dimension model. The results show that the trend and magnitude of the two method are extremely similar, which indicates that distortion prediction by finite elements analysis is reasonable.Abaqus software package is used to predict the beam distortion. In reality, some improvements are done in the factory. The results show that cutting technique can control some distortion, while reducing initial residual stress of the bulk can control distortion significantly. Moreover, changing the fixture from lying to standing is raised. |
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