Case Study 2.3: Distortions in Aeronautical Structural Parts

Abstract

The structural components employed for the aeronautical industry show highly restrictive requirements concerning their weight and strength capabilities. Following these requirements, they usually have a slender nature, showing a highly unsymmetrical ribbed geometry. This point coupled with the residual stresses present on the stocks from which these parts are machined, cause that the final machined parts show distortion problems that can make them unacceptable and, thus, generate the rejection of the manufactured component. Within the INTEFIX project, a solution has been developed comprising the use of fixtures coupled with calculation engines for tackling the manufacturing of this kind of parts. Taking into account the actual residual stress state for the stock, a software tool has been developed that is capable to automatically clamp the part in the optimal way and machine the part assuring the minimum distortion for the machined component. When developing this tool, the requirement for its usage by low skilled operators at workshop level has been taken into account, guaranteeing its usability in actual manufacturing environments.