Machining allowance analysis and optimization of irregular shaped component in high speed aero-vehicle

Aiming at the problem of high scrap rate in high speed aero-vehicle caused by non-circular shaped component, large machining deviations of thin-walled manufacturing and uneven wall thickness, a numerical analysis method for component allowance modeling was proposed with blank/part 3D model machining as the core. A 3D point-cloud model for blank case was obtained by precision technology, and the space matching alignment principle for blank/part point-cloud was built which was enhanced by adding containment, alignment and balance as the constraints. Thus the optimization analyses for blank/part matching alignment and 3D machining allowance were realized. By using reference conversion principle, the transformation from virtual design references to entity reference of machining was achieved, which laid foundation for machining application. A case study of blank machining of a thin-walled and irregular-shaped aerospace component was taken to verify the proposed method, and the result showed the effectiveness and advantage on accuracy and efficiency than traditional manual methods.