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State-space theory–based closed-loop control of machining error of thin-walled part modeling and application

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Abstract

The thin-walled part is a key component in the aerospace field. However, its low stiffness makes it highly susceptible to deformation during milling. An adaptive compensation method for machining deformation based on state-space control is proposed to aim at the problem of precise wall thickness control of large thin-walled parts. Firstly, based on the state space theory, a closed-loop control model for machining errors of thin-walled parts is established. Taking the overall deformation and the cutter-relieving deformation into consideration comprehensively, a tool position compensation model considering the overall deformation is established, and the structural deformation is compensated based on the dimension correlation. Secondly, the influencing factors of the cutter-relieving deformation are analyzed, and the error model of the deformation during machining is established. The parameters are predicted based on the multi-round on-machine measurement (OMM) data; considering the coupling effect of the compensation value and the cutter-relieving deformation, the compensation value calculation that meets the expected machining wall thickness is realized. Finally, a measurement and processing test is carried out on a certain type of rocket fuel tank to verify the feasibility and effectiveness of the proposed method. The experimental results show that the compensation tool position trajectory based on state-space control can adapt to the deformation state of the actual parts, and the machining accuracy of the fuel tank has been significantly improved.

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Acknowledgements

The authors thank the anonymous referees and editors for their valuable comments and suggestions.

Funding

This research was supported by the National Key Research and Development Project (no. 2022YFB3404704), the National Key Research and Development Project (no.2019YFA0709003) and the Changjiang Scholar Program of Chinese Ministry of Education (nos. Q2021053, T2017030).

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

    Haibo Liu, Xingliang Chai, Jianchi Yu, Qile Bo, Xu Li, Chenglong Wang, Te Li & Yongqing Wang

Authors
  1. Haibo Liu
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  2. Xingliang Chai
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  3. Jianchi Yu
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  4. Qile Bo
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  5. Xu Li
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  6. Chenglong Wang
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  7. Te Li
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  8. Yongqing Wang
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Contributions

Haibo Liu, Qile Bo, and Xu Li contributed the central idea. Xingliang Chai established the theoretical model and wrote the initial draft of the paper. Te Li and Yongqing Wang designed the experiment and analyzed most of the data. Chenglong Wang and JianChi Yu performed the experiment operation.

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Correspondence to Qile Bo.

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Liu, H., Chai, X., Yu, J. et al. State-space theory–based closed-loop control of machining error of thin-walled part modeling and application. Int J Adv Manuf Technol 127, 1721–1735 (2023). https://doi.org/10.1007/s00170-023-11542-7

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  • DOI: https://doi.org/10.1007/s00170-023-11542-7

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