Abstract
In machining of thin-walled large parts in aerospace industry, workpiece distortions occur during and after the processes due to residual stresses which are introduced or set free by the material removal process. These distortions lead to an inacceptable shape and geometric errors of the produced components and, thus, to deficient products. Considering that milling operations at large aerospace structural parts take several hours and that often expensive workpiece materials (such as titanium alloys) are used, these critical deformations cause high costs in the manufacturing companies. In some cases, post-treatments such as shot peening is applied in order to reduce the influence of residual stresses. This also means a significant increase of production costs of the parts. With the aim to overcome these challenges of part deformations, in this case study an intelligent fixture was developed which detects the tendency of workpiece distortions within sequenced processing steps and which allows an active adjustment of the clamping conditions in order to compensate for the influences of residual stresses on the final shape of the part.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Notes
References
Cerutti, X., Arsene, S., Mocellin, K.: Prediction of machining quality due to the initial residual stress redistribution of aerospace structural parts made of low-density aluminium alloy rolled plates. J. Mater. Form, Int (2015). doi:10.1007/s12289-015-1254-7
Denkena, B., Nespor, D., Böß, V., Köhler, J.: Residual stresses formation after re-contouring of welded Ti-6Al-4 V parts by means of 5-axis ball nose end milling. CIRP J. Manufact. Sci. Technol. 7, 347–360 (2014)
Denkena, B., Boehnke, D., de Leon, L.: Machining induced residual stress in structural aluminum parts. Prod. Eng. Res. Devel. 2, 247–253 (2008)
Möhring, H.-C., Brecher, C., Abele, E., Fleischer, J., Bleicher, F.: Materials in machine tool structures. CIRP Ann. Manuf. Technol. 64(2), 725–748 (2015)
Leopold, M., Hense, R., Möhring, H.C., Kersting, P.: Intelligente Werkstückspannsysteme für die verzugsfreie Fertigung dünnwandiger Aluminiumbauteile. Tagungsband 12. Magdeburger Maschinenbau-Tage, Magdeburg (2015)
Möhring, H.-C., Wiederkehr, P., Leopold, M., Nguyen, L.T., Hense, R., Siebrecht, T.: Simulation aided design of intelligent machine tool components. J. Mach. Eng. 16(3), 5–33 (2016)
Möhring, H.-C., Wiederkehr, P.: Intelligent fixtures for high performance machining. Procedia CIRP 46, 383–390 (2016)
Möhring, H.-C., Wiederkehr, P.: Intelligent Components for Self-Optimizing Machine Tools—BASIS FOR INDUSTRIE 4.0. Wiener Produktionstechnik Kongress, Vienna, Austria (2016), 28–29 Sept 2016
Sederberg, T.W., Parry, S.R.: Free-form deformation of solid geometric models. SIGGRAPH Comput. Gr. (ACM) 20(4), 151–160 (1986)
Schaefers, D.: Effiziente Stabilitätsvorhersage für Fräsprozesse durch Berechnung von Stabilitätskarten für unterschiedliche Eingriffssituationen, Master thesis (2014)
Coffignal, G., Lorong, P., Planchat, J., Yaqub, S., Larue, A.: Virtual machining: a general approach to deal with flexible workpieces. In: Proceedings of the 10th International Workshop on Modeling of Machining Operations. University of Calabria (Italy) (2007)
Denkena, B., Schmidt, C.: Experimental investigation and simulation of machining thin-walled workpieces. Prod. Eng. Res. Devel. 1(4), 343–350 (2007)
Kersting, P., Odendahl, S.: Capabilities of a process simulation for the analysis of five-axis milling processes in the aerospace industry. In: Proceedings of the 18th International Seminar on High Technology. Piracicaba, Brazil (2013)
Siebrecht, T., Odendahl, S., Hense, R., Kersting, P.: Interpolation method for the oscillator-based modeling of workpiece vibrations. In: Proceedings of the 3rd International Conference on Virtual Machining Process Technology, Calgary (2014)
Hense, R., Siebrecht, T., Wiederkehr, P.: Simulation of workpiece vibrations in spindle direction during milling. Appl. Mechan. Mater. (2016)
Wiederkehr, P., Siebrecht, T.: Virtual machining: capabilities and challenges of process simulations in the aerospace industry. Proc. Manuf. 6, 80–87 (2016)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Copyright information
© 2018 Springer International Publishing Switzerland
About this chapter
Cite this chapter
Möhring, HC., Wiederkehr, P., Leopold, M., Hense, R., Hannesen, F. (2018). Case Study 2.1: Detection and Compensation of Workpiece Distortions During Machining of Slender and Thin-Walled Aerospace Parts. In: Intelligent Fixtures for the Manufacturing of Low Rigidity Components. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-319-45291-3_4
Download citation
DOI: https://doi.org/10.1007/978-3-319-45291-3_4
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-45290-6
Online ISBN: 978-3-319-45291-3
eBook Packages: EngineeringEngineering (R0)