Machining Deformation Analysis Of Large-Scale Aluminum Alloy Integrated Structural Part

Aluminum alloy integrated structural parts are used more and more widely because of itssuperior performance. However, the initial residual stress and initial warp generated during asequence of processes including rolling, quenching, aging, pre-stretching and others causemachining deformation and out-of-tolerance of structural part. The releases of blank initialresidual stress in machining will cause macroscopic bending deformation. The initial warpwill cause clamping deformation when positioning and holding structural part. Both theminfluence greatly machining quality and production ability of enterprise. Therefore, it isnecessary to study machining deformation regularity of aluminium alloy integrated structuralpart to improve machining accuracy of structural part.The analytical method and finite element method are applied to analyze the machiningdeformation result from one-way residual stress, and the correctness of finite method isverified. The geometric model of structural part is established in Pro/E, the machiningdeformation under the action of residual stress is simulated in HyperMesh and ABAQUS toanalyze machining deformation regularity.The solutions of vacuum adsorption clamping and rolling fixture are studied to improvethe machining accuracy of integrated structural part. The structure of vacuum adsorptionsystem is designed including the tong and seal key components. The nitrile rubber is chosenas sealing material according to performance requirement of sealing. The material parametersin Mooney-Rivlin model are confirmed, and the material model of rubber is established. Thefinite element model of vacuum adsorption fixture is established in ABAQUS software. Themachining error of integrated structure part is analyzed by simulating working process ofvacuum adsorption fixture.The2D rolling FEM model is built according to the mathematical analysis. The stressand rolling depth are investigated under different rolling force, roller diameter and blankthickness. The rolling clamping process of integrated structural part is simulated to analyzemachining error in rolling clamping.The results show that both of vacuum adsorption fixture and rolling fixture can improvestructure part’s machining quality and production ability. However, vacuum adsorptionfixture is the better solution for working more stably, load uniformly, and no vibration inmachining process.