Case Study 2.4: Machining of Aircraft Turbine Support Structures

Abstract

The manufacturing chain of metallic components normally involves various processes like welding, machining or thermal treating. This combination leads to internal residual stresses that commonly result in deformations and distortions of the workpiece affecting the manufacturing precision and the quality of the component. This problem is especially relevant in large, slender and complex workpieces like those manufactured in the aeronautic industry. In this case study, the fixture development was oriented to the control and minimization of the deformation of a large component of an aircraft engine during the setup and clamping process to improve the precision during the machining process. The initial state of the component is an already deformed geometry as a consequence of previous welding processes; so, the objective is the development of an intelligent fixture able of clamping the deformed component without producing additional geometrical distortions. This chapter covers the development of a solution for the clamping of deformed components and the results obtained in the experiments.