多工序加工过程的飞机结构件变形预测与控制方法

doi:10.3901/JME.2025.23.361

摘要/Abstract

摘要： 飞机结构件的高速铣削过程中，加工工序与装夹方式的不同，将导致残余应力的释放不同，最终零件的加工变形也不一样。为此，开展多工序加工中飞机结构件的应力释放机理分析与工序变形预测，是进行加工质量控制的核心环节和基础。考虑残余应力释放对加工变形的影响，建立了加工变形力学模型及有限元分析方法，实验结果表明加工变形的模型计算值与实验值非常吻合，最大误差不超过9%；通过定义工序余量、工序总余量和总加工余量，建立了工序变形的递推计算模型，获得了飞机结构件最终的加工变形仅与最后一道工序、关键加工步骤有关这一规律。提出了关键加工步骤的工序总余量的优化模型及其步长递减算法，并对典型的三框结构件多工序加工过程进行了工序优化，结果表明：优化后的工序能够将三框结构件加工变形减小99%左右。

关键词: 飞机整体结构件, 残余应力, 加工方案, 工序总余量, 步长递减算法

Abstract: In the high-speed milling process of aircraft structural parts, the different machining processes and clamping methods will lead to different residual stress releases, and the processing deformation of the final parts will also be different. Therefore, the analysis of the stress relief mechanism and the prediction of process deformation of aircraft structural parts in multi-process processing are the core links and basis for processing quality control. Firstly, the residual stress which would affect the machining deformation should be considered, the mechanical model and finite element analysis method of machining deformation are established, and the experimental results show that the calculated value of the model of machining deformation is very consistent with the experimental value, and the maximum error is not more than 9%;Then, by defining the process margin, total process margin, and total machining margin, a recursive calculation model for process deformation is established, revealing that the final machining deformation of aircraft structural components is only related to the last process and key machining steps. Finally, the optimization model of the total operation margin of the key processing steps and its step decreasing algorithm are proposed, and the process optimization is carried out on the multi-process machining process of the typical three-frame structural parts, and the results show that the optimized process can reduce the machining deformation of three-frame structural parts by about 99%.

Key words: aircraft aeronautical monolithic component, residual stress, machining scheme, total process allowance, step reduction algorithm

中图分类号:

TH161

秦国华, 王纪国, 林锋, 吴竹溪. 多工序加工过程的飞机结构件变形预测与控制方法[J]. 机械工程学报, 2025, 61(23): 361-372.

QIN Guohua, WANG Jiguo, LIN Feng, WU Zhuxi. Prediction and Control Method for Deformation of Aeronautical Monolithic Components in Multi Process Processing[J]. Journal of Mechanical Engineering, 2025, 61(23): 361-372.

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