A Structural Topology Optimal Design Approach to Machining Deformation Control for Aeronautical Monolithic Components

doi:10.3901/JME.2019.21.127

Abstract

Abstract: In the manufacturing process of blank, the non homogeneity of mechanical properties of the material can produce the residual stress in the aluminum alloy thick plate. During the following high speed cutting process with the removal of the material, the release of residual stress can cause the deformations of the aeronautical monolithic component. It will seriously affects the size stability of the aeronautical monolithic component. Under the assumption of the unchanged magnitude and distribution of the initial residual stress, the workpiece deformation is not uniform with various workpiece structure. Therefore, the effect of residual stress release on machining deformations of various structures is investigated to guarantee the machining quality. It is very crucial for the realization of machining process with high efficiency and precise. Above all, according to separation of a blank into removed materials and formed workpiece, the analytical model of machining deformations is deduced by the bend deformation theory as well as the finite element method. The experiment of machined workpieces, carried out in NC machining factory, shows that both the amplitude and deformation curve, the simulated results are complete agreement with the analytical data. But the twos are less than 10% difference of the amplitude with the experimental values. And then, under the constraint of a given volume ratio, a topology optimal design model is established for the minimum machining deformation. By a series of explicit sub-problems approximating the objective and constraint functions, MMA solution technology is suggested for the presented topology optimal design model. Finally, the presented topology optimal design model is used to calculate the straight beam of C919. The machining deformation of the optimized structure is 0.7414 mm whereas the machining deformation of the un-optimized structure is 22.02 mm. Under the condition of the same material removals, the optimized structure can decrease 96.63% machining deformations.

Key words: aeronautical monolithic component, initial residual stress, machining deformation, topology optimization, MMA algorithm

CLC Number:

TG702

WANG Huamin, QIN Guohua, HU Zheng, LIN Feng, WU Zhuxi, HAN Xiong. A Structural Topology Optimal Design Approach to Machining Deformation Control for Aeronautical Monolithic Components[J]. Journal of Mechanical Engineering, 2019, 55(21): 127-138.

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