A collaborative optimization method of machining sequence for deformation control of double-sided structural parts
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ORIGINAL ARTICLE
A collaborative optimization method of machining sequence for deformation control of double-sided structural parts Xiaozhong Hao 1 & Yingguang Li 1 & Yang Ni 1 & Mengqiu Li 1 & Changqing Liu 1 Received: 7 December 2019 / Accepted: 17 August 2020 / Published online: 18 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract An appropriate machining sequence can benefit the deformation control of structural parts. However, the existing machining sequence optimization methods can only take single-sided parts into consideration, which is not sufficient to the deformation control of the double-sided parts. To this end, this paper proposes a double-sided collaborative optimization method of machining sequence for deformation control of structural parts. Off-line numerical analysis and on-line deformation monitoring are combined in the proposed method, i.e., the relative residual stiffness of the workpiece in different machining sequence is obtained by off-line numerical analysis, and the residual stress distribution is reflected by on-line deformation monitoring data, respectively. Then, a fuzzy comprehensive evaluation model aiming to decrease the overall deformation is established to realize the collaborative optimization of machining sequence. The machining efficiency is also considered in this model by optimizing the number of alternate flip-over, where the machining features of the part with two sides are machined alternatively according to the optimized sequence. The experiment shows that the proposed collaborative optimization method of machining sequence can decrease the machining deformation of double-sided parts effectively. Keywords Structural parts . Deformation control . Machining sequence optimization . Double-sided machining . Fuzzy comprehensive evaluation
1 Introduction Machining deformation is a significant problem in manufacturing industry, especially for the machining of thinwalled aviation structural parts. The EU and the USA had initiated “COMPACT (A Concurrent Approach to Manufacturing Induced Part Distortion in Aerospace Components, 2005–2009)” and “MAI I-III (Metals Affordability Initiative, 1999–2016)” to study machining deformation control. Many factors, including the initial residual stress of workblank [1], part size and structure [2], machining process [3], etc., can affect machining deformation. Additionally, due to large amount material removal for aviation structural parts, the part stiffness becomes weak and
* Yingguang Li [email protected] 1
National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
larger deformation will happen in the finishing stage. In order to meet the requirement of higher performance of new generation aircrafts, the design of aviation structural parts tends to be large in size, modular in function, and complicated in structure [4, 5]. Meanwhile, lots of parts are designed with machining features on both top and under
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