An analytical model to predict the machining deformation of frame parts caused by residual stress

In recent years, greater attention has been given to predicting and controlling machining deformation (MD), with a major factor in this being residual stress (RS), a primary concern in the processing of aerospace monolithic thin-walled parts. This paper proposes an analytical model for frame parts MD that can predict deformation caused by RS; a slope method is then presented for measuring the distribution of the blank initial RS. Accuracy for the proposed model is validated via experiments and finite element simulations. Following this is a study of the effects of neutral layer offset and RS on the deformation, as well as a determination of the functional relationships between deformation and RS. Machining deformation is controlled by two methods, with the part's best position in the blank being optimized to minimize deformation and strain energy. Datum correction is used to effectively control the MD during the finishing stage.