Simulation of part distortion in milling operation of forged aerospace components using boolean subtraction

Abstract

Aerospace industry requires the production of complex, multi-functional components with very low geometrical tolerances using difficult to machine materials such as Ti-6Al-4V. One of the main challenges when machining such materials is the resulting part distortion after milling due to the release of residual stresses generated in previous manufacturing steps such as forging or heat treatment. To prevent costly scrap parts and manual rework, finite element method (FEM) can be utilized to predict resulting part distortion during the machining process development phase. This paper presents a novel approach for part distortion simulation by directly integrating relevant machining data from computer aided manufacturing (CAM) system for the FEM using Boolean subtraction operations. A developed software interface enables a step-by-step mechanical material removal simulation providing manufacturers with an efficient and flexible tool for automated process evaluation. The approach is implemented in a laboratory setup using commercial CAM and FEM systems and evaluated by using aerospace relevant demonstration parts.