Online Prediction of Machining Distortion of Aeronautical Parts Caused by Re-Equilibration of Residual Stresses

Abstract:

This paper is concerned with the prediction of part distortion induced by residual stress relief during machining. Aeronautical manufacturing requires nowadays the production of large monolithic parts from workpieces obtained by forging or rolling operations. Residual stresses induced during these forming steps are often consequent and represent a significant obstacle for manufacturers. Re-equilibration of initial residual stresses induced by material removal causes the part to deform.The method presented in this paper provides a tool for predicting changes in the geometry of the part occurring during machining and after unclamping. This prediction is based on an on-line data acquisition. From the predicted shape, the manufacturer is able to anticipate extra conforming steps eventually required afterwards and an updated toolpath accounting for geometrical changes happening during the on-going operation can be derived.The impact of the unknown initial residual stresses on the part deformation during machining is predicted on-line by comparing measured deformations to a reduced basis of mechanically admissible evolutions for the part geometry induced by material removal. This reduced basis is extracted from a larger database constructed off-line thanks to machining simulations and observations of previously machined similar parts.An auxiliary database for post-machining distortion is constructed similarly and makes possible a quick and reliable on-line prediction of the final shape of the part (i.e. after unclamping).

• Periodical: Key Engineering Materials (Volumes 611-612)
• Pages: 1327-1335
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.611-612.1327
• Online since: May 2014
• Authors: Fabien Poulhaon*, Matthieu Rauch, Adrien Leygue, Jean Yves Hascoet, Francisco Chinesta
• Keywords: Part Distortion, POD, Residual Stress

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