Modeling the Varying Dynamics of Thin-Walled Aerospace Structures for Fixture Design Using Genetic Algorithms
Fixture design for milling of aerospace thin-walled structures is a challenging process due to the high ﬂexibility of the structure and the nonlinear interaction between the forces and the system dynamics. At the same time, the industry is aiming at achieving tight tolerances while maintaining a high level of productivity. Numerical models based on FEM have been developed to simulate the dynamics of thin-walled structures and the effect of the ﬁxture layout. These models require an extensive computational effort, which makes their use for optimization very unpractical. In this research work, a new concept is introduced by using a multi-span plate with torsional and translational springs to simulate the varying dynamics of thin-walled structure during machining. A formulation, based on holonomic constraints, was developed and implemented to take into account the effect of rigid ﬁxture supports. The developed model, which reduces the computational time by one to two orders of magnitude as compared to FE models, is used to predict the dynamic response of complex aerospace structural elements including pockets and ribs while taking into account different ﬁxture layouts. The model predictions are validated numerically. The developed model meets the conﬂicting requirements of prediction accuracy and computational efﬁciency.
M. Meshreki et al., "Modeling the Varying Dynamics of Thin-Walled Aerospace Structures for Fixture Design Using Genetic Algorithms", Advanced Materials Research, Vol. 223, pp. 652-661, 2011