Low-stiffness spring element constraint boundary condition method for machining deformation simulation
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DOI 10.1007/s12206-020-0905-x
Journal of Mechanical Science and Technology 34 (10) 2020 Original Article DOI 10.1007/s12206-020-0905-x Keywords: · Initial residual stress · Low-stiffness spring element · Boundary conditions · Machining deformation simulation · Aluminum alloy
Correspondence to: Qiong Wu [email protected]
Low-stiffness spring element constraint boundary condition method for machining deformation simulation He-chuan Song1,2, Yi-du Zhang1,2, Qiong Wu1,2 and Han-jun Gao1,2 1
State Key Laboratory of Virtual Reality Technology and Systems, Beijing University of Aeronautics and 2 Astronautics, Beijing 100191, China, School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing 100191, China
Abstract
Citation: Song, H., Zhang, Y., Wu, Q., Gao, H. (2020). Low-stiffness spring element constraint boundary condition method for machining deformation simulation. Journal of Mechanical Science and Technology 34 (10) (2020) 4117~4128. http://doi.org/10.1007/s12206-020-0905-x
Received December 29th, 2019 Revised
April 19th, 2020
Accepted July 25th, 2020 † Recommended by Editor Chongdu Cho
The 3-2-1 constraint principle has been widely applied as the boundary conditions for the finite element method (FEM) to simulate machining deformation of aerospace structure components. However, this principle is inconsistent with the actual contact surface between workpieces and worktables because it provides only three constraint points. These points have rarely been studied in terms of positions and distances. In addition, the applicability of the principle is limited for the workpiece with geometric centers difficult to find or centers without nodes. Therefore, this study proposed a new boundary condition method, low-stiffness spring element constraint method (SECM), drawing on FEM theories and related mechanic theories. With the method proposed this study established the FE model of machining deformation, and then compared the simulation results with both the analytical results and the experimental results of milling and deformation measurements. Good agreement is found between the three results. Finally, this study examined the effect of the three constraint points on simulation of the 3-2-1 principle in terms of point positions and distances. A comparison between SECM and the 3-2-1 principle revealed that SECM is closer to the actual working conditions and more reliable with wider application, which suggests that SECM can replace the 3-2-1 principle as the boundary conditions for the workpiece.
1. Introduction
© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2020
Large monolithic components have been increasingly widely used in the aerospace field because of their compact structure, ability to save materials, and light weight [1]. However, these components suffer from complex structures, large sizes and high material removal rates. In addition, dimensional accuracy and performance of these components can be ser
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