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Studying control strategies for dimensional precision in aerospace parts machining

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Abstract

Dimensional instability in machined aerospace parts is a complex engineering problem which is contributed by many factors. Mainly, the machining stresses developed during the part’s material cutting, cause dimensional imperfections. The complex interaction of mechanical, thermal, and metallurgical transformations makes it difficult to establish the exact reasoning of part’s desired dimensional instability. The research work presented here deals with the investigations of machining stresses and subsequent dimensional deformations in aerospace grade aluminum alloys. A commercial finite analysis code is applied to simulate the residual stresses and machining process. The stress profiles developed from the numerical simulations are compared with standard curves. The actual machined part’s deviations are measured on a CMM (coordinate measuring machine). The experimental and numerical results are found consistent with each other. This validates the control strategies adopted to simulate the machining stresses and resultant deformations.

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Abbreviations

Fi :

Internal forces at equilibrium state

Mi :

Internal moment at equilibrium state

h:

Thickness of removed material layer

hn :

Thickness before the nth layer

hn+1 :

Thickness after removal of nth layer

σj :

Residual stress of nth layer

E:

Young’s modulus

h:

Thickness of the removed layer

Sn :

Stress after removed material layer

K (T):

Thermal conductivity, Wm−1 K−1

ρ:

Density, kgm−3

c:

Specific heat, J kg−1 K−1

q:

Internal heat generation in Wm−3

α:

Coefficient of thermal expansion

ε:

Total strain tensor

εe :

Elastic strain tensor

εth :

Thermal strain tensor

εp :

Plastic or inelastic strain tensor

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Jeddah, Jeddah, Saudi Arabia

    Waqas Saleem, Hassan Ijaz & Muhammad Zain-ul-Abdein

  2. Department of Chemical and Materials Engineering, King Abdulaziz University, Jeddah, Saudi Arabia

    Aqeel Ahmed Taimoor

  3. Department of Mechanical Manufacturing and Automation, Beihang University, Beijing, China

    Yunqiao Wang

Authors
  1. Waqas Saleem
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  2. Hassan Ijaz
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  3. Muhammad Zain-ul-Abdein
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  4. Aqeel Ahmed Taimoor
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  5. Yunqiao Wang
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Correspondence to Waqas Saleem.

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Saleem, W., Ijaz, H., Zain-ul-Abdein, M. et al. Studying control strategies for dimensional precision in aerospace parts machining. Int. J. Precis. Eng. Manuf. 18, 39–47 (2017). https://doi.org/10.1007/s12541-017-0005-8

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  • DOI: https://doi.org/10.1007/s12541-017-0005-8

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