Residual stresses evolution mechanism of thin-walled component and deformation control method

Deformation is one of the most important challenges in the machining of the thin-walled component, especially for the complicated thin-walled component with difficult-to-machining material. The internal stress and machining induced residual stress are evolved during the machining process, causing the poor machining accuracy of the final component. To solve this problem, a deformation control method based on the evolution mechanism of residual stress is proposed. Firstly, the simplified model of the component is obtained through the slice method. The equilibrium equation for clamping point is established by analyzing the loads distribution. The geometric equilibrium equation is then obtained according to the deformation superposition principle and micro deformation theory. The distribution of loads at different instants of machining process is analyzed, and the evolution mechanism of the residual stresses and the equivalent loads is revealed. Secondly, a mathematical model is established to regulate the in-process deformation of the thin-walled component. As the result, the evolution of the residual stresses and the deformation of the final component is controlled. Finally, 3 deformation validation experiments are carried out to process the same thin plates, and the deformation of the thin plates are compared. The experimental results indicate that the maximum deformation can be reduced by 82.2%.