A machining deformation control method of thin-walled part based on enhancing the equivalent bending stiffness

• Published in: International journal of advanced manufacturing technology Vol. 108; no. 9-10; pp. 2775 - 2790
• Main Authors: Li, Bianhong, Gao, Hanjun, Deng, Hongbin, Wang, Chao
• Format: Journal Article
• Language: English
• Published: London Springer London 01.06.2020; Springer Nature B.V
• Subjects: Bending; CAE) and Design; Computer-Aided Engineering (CAD; Control methods; Deformation; Engineering; Equivalence; Industrial and Production Engineering; Machine shops; Machining; Mechanical Engineering; Media Management; Original Article; Residual stress; Stiffening; Stiffness; Stress relaxation; Workpieces; Deformation change regulations with time; Machining deformation control; Equivalent bending stiffness; Thin-walled parts; Residual stress
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-020-05585-3

In the current study, the experiments are conducted to firstly measure the machining deformation change regulations of two typical thin-walled parts during 1–720 h after machining. Results demonstrate that the deformations of the specimens evidently change in 1–72 h after machining due to the residual stress relaxation. The specimens reach a relatively stable state at 72 h and deformed slowly in 72–720 h. Subsequently, a 3-step machining process was proposed to control the final deformation of two groups of thin-walled specimens. The process was shown as follows: (1) fabricating the workpiece with the extra stiffening ribs in the first-time machining; (2) placing the workpiece freely for 72 h or conducting stress relief process; and (3) machining the reserved stiffening ribs in the second-time machining. Compared with the conventional machining method, the final maximum machining deformations of specimens in group 1 and 2 manufactured by the 3-step machining process are reduced by 29.68% and 48.09%, respectively. Eventually, a machining deformation control method of thin-walled parts based on enhancing the equivalent bending stiffness was summarized and proposed. Graphical abstract