Deformation analysis and error prediction in machining of thin-walled honeycomb-core sandwich structural parts

  • Gaoqun Liu
  • Zhengcai Zhao
  • Yucan Fu
  • Jiuhua Xu
  • Zhiqiang Li


Due to its low rigidity and poor stiffness, machining deformation in numerical control milling is a big obstacle to achieve accurate shape of thin-walled honeycomb-core sandwich structural parts. In this paper, the factors which affect the machining deformation of these structural parts are analyzed at first. Then, a finite element analysis model is established, which considers the affecting factors of workpiece original stress, fixture constraints and cutting forces, to simulate the magnitude and distribution of the machining deformation. Afterwards, a prediction model is developed by using back propagation neural network to build the relationship between the deformation and machining parameters. Finally, the milling and measurement experiments are performed to validate the proposed prediction model. By comparing the experimental result with the simulation result and the prediction result, it is found that the experimental result was 7.2 and 2.2% less than the simulation result and the prediction result, respectively. Thus, a conclusion is drawn that the machining deformation prediction methodology is feasible.


Thin-walled parts Hollow structure Deformation prediction Sandwich structure Finite element method (FEM) 


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Funding information

The authors gratefully acknowledge the financial support of the National Natural Science Foundation of China (No.51475233), the Fundamental Research Funds for Central Universities (No.NZ2016107), and the Jiangsu Innovation Program for Graduate Education (No.CXLX13_139).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2017

Authors and Affiliations

  • Gaoqun Liu
    • 1
    • 2
  • Zhengcai Zhao
    • 1
  • Yucan Fu
    • 1
  • Jiuhua Xu
    • 1
  • Zhiqiang Li
    • 3
  1. 1.College of Mechanical and Electrical EngineeringNanjing University of Aeronautics and AstronauticsNanjingChina
  2. 2.Nanjing Engineering Institute of Aircraft SystemNanjingChina
  3. 3.Beijing Aeronautics Manufacturing Technology Research InstituteBeijingChina

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