Articles | Volume 14, issue 2
https://doi.org/10.5194/ms-14-557-2023
https://doi.org/10.5194/ms-14-557-2023
Research article
 | 
15 Dec 2023
Research article |  | 15 Dec 2023

Machining distortion control of long beam parts based on optimal design of transition structure

Long-Xin Fan, Ning Han, and Yi Zhang

Related subject area

Subject: Machining and Manufacturing Processes | Techniques and Approaches: Optimization
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Cited articles

Akhtar, W., Ismail L., and Steven, Y. L.: Prediction and control of residual stress-based distortions in the machining of aerospace parts: A review, J. Manuf. Process., 76, 106–122, https://doi.org/10.1016/j.jmapro.2022.02.005, 2022. 
Arrazola, P. J., Özel, T., Umbrello, D., Davies, M., and Jawahir, I. S: Recent advances in modelling of metal machining processes, Cirp Annals, 62, 695–718, https://doi.org/10.1016/j.cirp.2013.05.006, 2013. 
Brinksmeier, E., Cammett, J. T., König, W., Leskovar, P., Peters, J., and Tönshoff, H. K.: Residual stresses – measurement and causes in machining processes, CIRP annals, 31, 491–510, https://doi.org/10.1016/S0007-8506(07)60172-3, 1982. 
Casuso, M., Polvorosa, R., Veiga, F., Suárez, A., and Lamikiz, A.: Residual stress and distortion modeling on aeronautical aluminum alloy parts for machining sequence optimization, Int. J. Adv. Manuf. Tech., 110, 1219–1232, https://doi.org/10.1007/s00170-020-05816-7, 2020. 
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Short summary
The presence of initial residual stress is a major contributor to machining distortion. To control machining distortion, the transition structure before the finishing stage is optimized in this paper. The first step is to create a machining distortion analysis model for long beam parts based on initial residual stress. The transition structure's topology optimization model is then established. Finally, a verification case is used. The proposed model is verified by simulation and experiments.