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New numerical approach for the modelling of machining applied to aeronautical structural parts

Abstract : The manufacturing of aluminium alloy structural aerospace parts involves several steps: forming (rolling, forging …etc), heat treatments and machining. Before machining, the manufacturing processes have embedded residual stresses into the workpiece. The final geometry is obtained during this last step, when up to 90% of the raw material volume is removed by machining. During this operation, the mechanical equilibrium of the part is in constant evolution due to the redistribution of the initial stresses. This redistribution is the main cause for workpiece deflections during machining and for distortions - after unclamping. Both may lead to non-conformity of the part regarding the geometrical and dimensional specifications and therefore to rejection of the part or additional conforming steps. In order to improve the machining accuracy and the robustness of the process, the effect of the residual stresses has to be considered for the definition of the machining process plan and even in the geometrical definition of the part. In this paper, the authors present two new numerical approaches concerning the modelling of machining of aeronautical structural parts. The first deals with the use of an immersed volume framework to model the cutting step, improving the robustness and the quality of the resulting mesh compared to the previous version. The second is about the mechanical modelling of the machining problem. The authors thus show that in the framework of rolled aluminium parts the use of a linear elasticity model is functional in the finite element formulation and promising regarding the reduction of computation times.
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Submitted on : Wednesday, June 6, 2018 - 4:21:32 PM
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Pierrick Rambaud, Katia Mocellin. New numerical approach for the modelling of machining applied to aeronautical structural parts. 21st International ESAFORM Conference on Material Forming, ESAFORM 2018, Apr 2018, Palermo, Italy. pp.Article number 070022, ⟨10.1063/1.5034918⟩. ⟨hal-01809367⟩



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