Key techniques in the process of simulating machining distortion in milling due to residual stresses were researched. The calculation program was developed to generate residual stresses file and the finite element model containing original residual stresses was established. The thin-walled structure was obtained after milling machining. In order to improve simulation accuracy, a new method was carried out to model the finite element model by combining solid-shell element with solid element. Considering the contact action by unilateral constraint between workpiece and baseplate when the workpiece was located by press clamps, contact method was put forward to simulate the effect of the compression only supported by thinking of workpiece as elastic body while workbase as rigid body. The modal analysis results of representative component based on finite element simulation were compared with experiment results. The validity and reliability were verified. The material removal was realized using element birth-death. The finite element simulation of machining distortion for aerospace structures was realized by using these techniques.
Zhang Hongwei, Zhang Yidu, Zhao Xiaoci, Wu Qiong.Key techniques in simulation of machining distortion for aeronautical monolithic component[J] JOURNAL OF BEIJING UNIVERSITY OF AERONAUTICS AND A, 2008,V34(02): 239-243
Brinmsmeier E,Hannover J,Cammett T,et al. Residual stress-measurement and cause in machining process[J].Annals of the CIRP.1982,31(2):491-509
Heiz A,Haszler A,Keidel C,et al. Recent development in aluminum alloy for aerospace application[J].Mater Sci Eng A,1999,A280:102-107
����.���ڲ���Ӧ���ͷ����طֲ��ı�������ӹ������о� .����:�������պ����ѧ��е���̼��Զ���ѧԺ,2005 Wang Zhaojun. Research on machining distortion based on the relief and redistribution of residual stresses . Beijing:School of Mechanical Engineering and Automation,Beijing University of Aeronautics and Astronautics,2005(in Chinese)
������.�������Ͻ�Ԥ��������Ӧ�����ӹ������о� .����:�������պ����ѧ��е���̼��Զ���ѧԺ,2006 Zhao Lili. Research on residual stresses & machining of machining deformation of aeronautic aluminum alloy pre-stretching board . Beijing:School of Mechanical Engineering and Automation,Beijing University of Aeronautics and Astronautics,2006(in Chinese)
����ΰ.���Ͻ�����ṹ��ϳ���ӹ�����Ӧ���������о� .����:�������պ����ѧ��е���̼��Զ���ѧԺ,2006 Dong Zhaowei.Study on the milling residual stress and deformation of the aluminum alloy integrated framework .Beijing:School of Mechanical Engineering and Automation,Beijing University of Aeronautics and Astronautics,2006(in Chinese)
������.���ں��տ���ṹ��ϳ���ӹ�����Ӧ���ͱ��λ�����о� . ����:�㽭��ѧ��е����Դ����ѧԺ,2003 Wang Litao. Study on residual stresses and distortion theory of aeronautica frame structure in the milling . Hangzhou:College of Mechanical and Energy Engineering, Zhejiang University, 2003(in Chinese)
��־��.���սṹ��ϳ���ӹ����ε�����Ԫģ�����ۼ������о� .����:�㽭��ѧ��е����Դ����ѧԺ,2003 Huang Zhigang.Study on finite element simulation of distortion due to milling process for aerospace molithic components . Hangzhou:College of Mechanical and Energy Engineering, Zhejiang University, 2003(in Chinese)
�����,��ӳ��,���ɷ�.7075���Ͻ��Ĳ���Ӧ������ݶȵ�����[J].����ѧ��,2003,24(4):336-338 Wang Qiucheng,Ke Yinglin,Zhang Qiaofang.Evaluation of residual stress depth profiling in 7075 aluminum alloy plates[J].Acta Aeronautica et Astronautica Sinica,2003,24(4):336-338(in Chinese)
Alves de Sousa R J, Yoon J W, Cardoso R P R, et al.On the use of a reduced enhanced solid-shell(RESS) element for sheet forming simulations[J]. International Journal of Plasticity,2007(23):490-515
Parente M P L, Fontes Valente R A,Natal Jorge R M, et al. Sheet metal forming simulation using EAS solid-shell finite elements[J].Finite Elements in Analysis and Design.2006,42:1137-1149
���ó�.����Ԫ��[M].����:�廪��ѧ������,2003 Wang Xucheng. Finite element method[M]. Beijing:Tsinghua University Press,2003(in Chinese)
����.����Լ��ϵͳ����ѧ�о���չ[J].��ѧ��ʵ��,2000,22(6):8-11 Zhang Yi. Advances in dynamics of systems with unilateral constraints[J].