A novel hybrid model for prediction of distortions in milling

Abstract

Distortion of machined monolithic thin-walled parts is a well-known issue and a perpetual concern in the aerospace industry. In this article, a novel analytical-FEM hybrid model for fast prediction of distortion of thin-walled parts is proposed. Moving cutting loads due to milling are calibrated and applied directly to the surface of the meshed model. The effects of measured initial stresses in the workpiece as well as cutting forces and heat flux are effectively modeled. Validation tests carried out on the aerospace alloy Al7050-T7451 showed the promise of the model in predicting the distortion of the part.