Monolithic aeronautical components have varying degrees and forms of machining deformation due to the coupling effect of various factors in Numerical Control (NC) machining. Rolling operation is an effective means to correct distortion of large aspect ratio thin-walled structures, and compressive stress is introduced to improve the service life and obtain the dimensional accuracy of the workpiece. At present, rolling correction depends mainly on the trial and error method based on workers' experience, and lack of accurate prediction method for the corrected load leads to poor quality stability. In this paper, the requirement for energy balance of a beam structure is analyzed. The equivalent section method and the bending strain energy method are used to calculate the bending strain energy and the rolling introduced energy, respectively. Then, a mathematical model for workpiece distortion and correction load is established to predict the correction load. To achieve rapid evaluation of accuracy of the correction load, the collaborative simulation environment of machining distortion-rolling correction is established by the direct stress method to realize fast-equivalent simulation of deformation of monolithic aeronautical components.The three-frame integral structure is used as an example to verify that the distortion elimination rate obtained by the simulation with the direct stress method is 94.5%. The experimental results show that the distortion elimination rate of single rolling is 82.0%, and the surface of the rolling area is changed from milling tensile stress to rolling compressive stress. The correction effect is in line with expectations.
LU Laixiao
,
SUN Jie
,
HAN Xiong
,
XIONG Qingchun
,
SONG Ge
. Load prediction method of rolling distortion correction for monolithic aeronautical components based on energy theory[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2017
, 38(12)
: 421326
-421326
.
DOI: 10.7527/S1000-6893.2017.421326
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