Key techniques in simulation of machining distortion for aeronautical monolithic component

Key techniques in the process of simulating machining distortion in milling due to residual stresses were researched. The calculation program was developed to generate residual stresses file and the finite element model containing original residual stresses was established. The thin-walled structure was obtained after milling machining. In order to improve simulation accuracy, a new method was carried out to model the finite element model by combining solid-shell element with solid element. Considering the contact action by unilateral constraint between workpiece and baseplate when the workpiece was located by press clamps, contact method was put forward to simulate the effect of the compression only supported by thinking of workpiece as elastic body while workbase as rigid body. The modal analysis results of representative component based on finite element simulation were compared with experiment results. The validity and reliability were verified. The material removal was realized using element birth-death. The finite element simulation of machining distortion for aerospace structures was realized by using these techniques.