Deformation control processing method for aircraft thin-wall weak-rigidity super-long beam structural member

Abstract

The invention belongs to the technical field of mechanical manufacturing equipment, and discloses a deformation control machining method for an aircraft thin-wall weak-rigidity super-long beam structural member. The deformation influence of the internal stress of the large-allowance process frame on the straightness and deflection of the thin-wall weak-rigidity super-long beam type structural part in the full-length range is avoided, the overall rigidity of the thin-wall weak-rigidity super-long beam type structural part in the machining process is enhanced, meanwhile, the material utilization rate is greatly increased, the cost is reduced, and meanwhile the machining efficiency is improved. And the machining quality and the production efficiency of parts are greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of mechanical manufacturing equipment technology, and specifically relates to a deformation control processing method for thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft. Background Technology

[0002] Currently, there are many types of aircraft parts known in this field, especially thin-walled, weakly rigid, ultra-long beam structural components, which have complex and irregular structures.

[0003] The machining process for complex structural components such as ultra-long beams in aircraft, especially complex thin-walled, weak-rigid ultra-long beams, is extremely complex. The deformation of the parts themselves and the severe vibrations in the weak-rigid areas have a significant impact on quality and machining cycle time, making them the most challenging problems in the machining process. The typical machining process involves pre-applying blank material to the theoretical shape of the part, and then repeatedly clamping and mounting it to achieve the machining. This method is time-consuming, labor-intensive, difficult, and inefficient. Summary of the Invention: To address the aforementioned problems, this invention provides a deformation control processing method for ultra-long, thin-walled, weak-rigid aircraft beam-type structural components. This method solves the problem that existing processing methods for complex aircraft parts, which rely on pre-reserved material overlaps on the theoretical surface of the part, lead to deformation of the part itself and severe vibrations in weak-rigid areas, affecting surface quality. The present invention utilizes an ultra-small overlap method, avoiding the influence of internal stress from large material margins on the straightness and deflection of ultra-long beam-type parts throughout their entire length. Simultaneously, it significantly improves material utilization, reducing costs while greatly enhancing the processing quality and production efficiency of the parts.

[0004] A deformation control machining method for aircraft weakly rigid ultra-long beam structural components, comprising the following steps: Step 1: For weakly rigid ultra-long beam structural components, allowances are made in the direction of the two side flanges and the height of the part according to the minimum process allowance requirements; Step 2: According to the minimum process allowance requirements, initially shape the raw material into a square to form a structural component; Step 3: Clamp the structural component with a vise and rough machine the groove on one side in the height direction; Step 4: Rotate the structural component 180° around its length axis, clamp the structural component with a vise, and perform rough machining on the other side of the cavity; Step 5: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine one side of the flange. Step 6: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine the other side of the wing surface; At this point, process overlaps naturally form around the structural components; Step 7: After completing the above steps, leave the container to stand still for 24 hours to allow it to naturally age. Step 8: Check the deformation along the entire length of the part, re-square the structural component based on the actual deformation, and correct the structural component datum by removing material. Step 9: Clamp the structural component with a pressure plate and repeat the machining operation in Step 3 to perform fine machining on this side cavity; Step 10: The structural component is rotated 180° around its length axis, and then clamped with a pressure plate to perform precision machining on the other side of the cavity. Step 11: Clamp the structural component with a pressure plate and repeat the machining operation in Step 5 to perform finishing on the theoretical shape of the airfoil; Step 12: Clamp the structural component with a pressure plate and repeat the machining operation in Step 6 to perform finishing on the theoretical shape of the airfoil; Step 13: The fitter removes the process overlap and grinds the cut surface smooth.

[0005] Furthermore, in step 1, the minimum process allowance is 5~10mm.

[0006] Furthermore, in step 2, the raw material is initially squared to indicate that the cross-section of the raw material is a regular square. The requirements for the perpendicularity and parallelism of the regular square are: less than 1 / 2 of the minimum process allowance.

[0007] Furthermore, in steps 3 and 4, a margin of more than 10mm is reserved during rough machining.

[0008] Furthermore, in steps 5 and 6, a 3-5 mm allowance is left on the wing surface during rough machining.

[0009] Furthermore, in steps 11 and 12, When repeating steps 5 and 6, because the process overlaps at the height of the flange, the clamping force is effectively transferred to the structural component body, the flange has good strength and rigidity, and the surface quality and processing efficiency are not affected.

[0010] Furthermore, in steps 11 and 12, a small cutting tool is used to machine the projected contour in the height direction of the edge plate, and small dimensional allowances are left at equal intervals in some areas to connect with the frame of the process joint.

[0011] The beneficial effects of this application are as follows: For thin-walled, weak-rigid, ultra-long beam-type structural components in aircraft, the original machining process had a lap size of no less than 60mm on each side. This was because the original process, in addition to considering clamping allowance, also had to consider the reserved toolpath size based on the diameter of the selected tool, resulting in significant material waste. The current process, where the lap overlaps onto the rib height, shows that both width and height are within the same horizontal reference plane when viewed from a cross-section. The advantage of this is that when adjusting the original two-station process of machining both sides to a four-station process with length as the axis of rotation, each station has a reliable positioning reference.

[0012] The process overlap proposed in this application, which overlaps the flange plate along its height, effectively overcomes the shortcomings of insufficient rigidity and strength during the finishing of thin-walled, weak-rigid flange plates in the entire machining process. In the original process, the process overlap is typically chosen to overlap the flange plate on both sides of the part. Thus, during machining, the thin-walled, weak-rigid flange plate, from a cross-sectional structural perspective, is equivalent to a cantilever beam with very weak structural rigidity lacking support at its far end. Therefore, the severe vibrations during machining significantly affect the part's machining quality and cutting efficiency.

[0013] In the processing technology of this application, the entire part machining process can be completed on a 3-axis machine, reducing reliance on 5-axis machines and fully freeing up the production capacity of high-precision feature equipment. By changing the overlap mode of the process joint, the superposition of vibrations during machining with excessively long overhanging tools and machining of weak rigid edge plates is avoided, effectively improving the surface quality of the parts and machining efficiency. Attached Figure Description

[0014] The accompanying drawings are provided to further understand the technical solutions of the present invention and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of the present invention and do not constitute a limitation on the technical solutions of the present invention.

[0015] Figure 1 This is a schematic diagram of a thin-walled, weakly rigid, ultra-long beam structure for aircraft, provided by an embodiment of the present invention. Figure 2 This is a schematic diagram of the original processing technology of the aircraft thin-walled, weakly rigid, ultra-long beam structure in an embodiment of the present invention. Due to the excessive length of the part, only a portion is shown for illustration. Figure 3 This is a cross-sectional schematic diagram of the original processing technology structure for thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft, provided in an embodiment of the present invention. Figure 4 This is a structural schematic diagram of the current process for thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft, provided by an embodiment of the present invention. Figure 5 This is a schematic cross-sectional view of the original process for the manufacturing of thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft, provided as an embodiment of the present invention. Figure 6A schematic diagram of the existing roughing process for thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft, provided for an embodiment of the present invention; Figure 7 A schematic diagram of the existing finishing process for thin-walled, weakly rigid, ultra-long beam-type structural components for aircraft, provided as an embodiment of the present invention; Explanation of reference numerals in the attached figures: 1. Aircraft thin-walled, weakly rigid, ultra-long beam parts; 2. Raw materials; 3. Process connectors; 4. Pressure plate grooves; 5. Part edge plates; 6. Left wing surface shape; 7. Right wing surface shape; 8. Part cavity; 9. Pressure plate; 10. Vise jaws. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0017] The terms "first," "second," etc., used in the specification and claims of this invention are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0018] As explained in the background section above, the processing difficulty of thin-walled, weak-rigid, ultra-long beam-type structural components for aircraft lies in the process of using pre-reserved blank process frames and repeatedly clamping the parts to achieve processing. This processing method makes it difficult to control the deformation of the parts, especially the process deformation after heat treatment, which is difficult to eliminate. The process preparation before processing is time-consuming and labor-intensive, the processing difficulty is high, and the processing efficiency is low.

[0019] To address the problems existing in the processing methods of thin-walled, weakly rigid, ultra-long beam structures for aircraft, this invention provides a deformation control processing technology for such structures, offering a novel approach and a convenient programming and processing method.

[0020] In this embodiment of the invention, a deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft is described, referring to... Figure 4-7 The steps are as follows: Step 1: For weakly rigid ultra-long beam structural components, allowances are made in the direction of the two side flanges and the height of the part according to the minimum clamping allowance requirements. Step 2: According to the minimum process allowance requirements, the raw material is initially squared, that is, the cross-section of the structural component is a regular square. This step has certain requirements for the perpendicularity and parallelism of the regular square, but they are not strict. Step 3: Clamp the structural component with a vise and rough machine one side of the groove in the height direction, leaving a margin of at least 10mm during rough machining. Step 4: Rotate the structural component 180° around its length axis, clamp the structural component with a vise, and rough machine the other side of the cavity, leaving a margin of more than 10mm during rough machining. Step 5: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine one side of the wing surface, leaving a 3-5mm allowance on the wing surface during rough machining; Step 6: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine the other side of the wing surface. Leave a 3-5mm allowance on the wing surface during rough machining. At this point, process overlaps naturally form around the structural components; Step 7: Steps 2 to 6 are to fully release the internal stress of the parts. After the above steps are completed, the parts are left to stand still for 24 hours to allow for natural aging.

[0021] Step 8: Inspect the deformation along the entire length of the part. Based on the actual deformation, reshape the raw material into a square and correct the part's reference datum by removing material. Do not forcibly correct it with a press, as this will create unknown internal stress in the part, and new deformation will occur after processing.

[0022] Step 9: Clamp the structural component with a pressure plate and repeat the machining operation in Step 3. At this time, perform the finishing machining of the side cavity. Since there is a margin on the outer flange, the flange has a certain strength and rigidity, and the surface quality and machining efficiency are not affected.

[0023] Step 10: The structural component is rotated 180° around its length axis. The structural component is then clamped with a pressure plate, and the groove on the other side is precision machined. At this time, since there is a margin on the outer flange, the flange has a certain strength and rigidity, and the surface quality and processing efficiency are not affected.

[0024] Step 11: Clamp the structural component with a pressure plate and repeat the machining operation in Step 5 to perform finishing on the theoretical shape of the airfoil. At this point, because the process overlap is at the height of the flange, the clamping force can be effectively transferred to the structural component body. The flange has good strength and rigidity, and the surface quality and machining efficiency are not affected. Use a small tool to machine the projected contour of the flange in the height direction, leaving small dimensional allowances at equal intervals for connection with the frame of the process overlap. Subsequently, the fitter will saw it off and grind the cut edges smooth.

[0025] Step 12: Clamp the structural component with a clamping plate and repeat the machining operation in Step 6 to perform finishing on the theoretical shape of the airfoil. At this point, because the process overlap is at the height of the flange, the clamping force can be effectively transferred to the structural component body. The flange has good strength and rigidity, and the surface quality and machining efficiency are not affected. Use a small tool to machine the projected contour of the flange in the height direction, leaving small dimensional allowances at equal intervals for connection with the frame of the process overlap. Subsequently, the fitter will saw it off and grind the cut edges smooth.

[0026] Step 13: The fitter removes the process overlap and grinds the cut surface smooth.

[0027] Traditional processing involves connecting multiple equally spaced process joints to the two flanges of the structural component to be processed, such as... Figure 1-3 As shown, process joint 3 is installed on the positioning pin hole 5 located on the same straight line to form the machining reference axis, and the other process joints 3 are distributed on both sides of the reference axis; the connection part of the process joint is located on the theoretical profile of the wing surface. The length of the process joint must take into account the clamping area of ​​the pressure plate, the avoidance area of ​​the tool path of the advance and retraction tool, and the material removal area of ​​the machining.

[0028] The existing process involves attaching the process connector to the height direction of the weak rigidity insulation plate.

[0029] In this application, the allowance for the overlap on one side is only 8-10mm, while in the original processing technology, the size of the overlap on one side is not less than 60mm. This is because the original process not only considers the clamping allowance but also the reserved toolpath size based on the diameter of the selected tool. Therefore, the original processing technology wastes a lot of materials.

[0030] In this application, the process overlap, which is placed along the height of the flange, effectively overcomes the shortcomings of insufficient rigidity and strength during the finishing of thin-walled, weak-rigid flanges in the entire machining process. The original process method typically overlaps the flange on the two sides of the part. In this way, from a cross-sectional structural perspective, the thin-walled, weak-rigid flange is equivalent to a cantilever beam with very weak structural rigidity lacking support at its far end. Therefore, the severe vibrations during machining significantly affect the part's machining quality and cutting efficiency.

[0031] Viewed from the cross-section, the width and height are both within the same horizontal reference plane. The advantage of this is that when adjusting the original two-station process of machining both front and back sides to a four-station process with length as the axis of rotation, each station has a reliable positioning reference.

[0032] This application, by changing the overlapping mode of the process joint, avoids the superposition of vibrations when machining with excessively long overhanging tools and machining weak rigid edge plates, effectively improving the surface quality of parts and machining efficiency.

[0033] The process overlap in this application utilizes the natural outward extension of the flange height to form an overlap area. After the theoretical surface of the part is machined, a small tool is used to machine the projected contour of the flange height as needed. A narrow rib is left at an appropriate position to maintain the connection between the overall frame formed by the overlap and the part at the CNC station. Subsequently, the fitter saws off the narrow rib, removes the process overlap, and grinds the cut edges to smooth them, thereby completing the entire machining of the part.

[0034] The deformation control machining process provided in this application involves attaching the process overlap to the height direction of the weakly rigid flange and adjusting the two-station machining process for both front and back surfaces to a four-station machining process with length as the axis of rotation. By using a small-sized process overlap, material is saved, and the influence of internal material stress on part deformation is avoided. Simultaneously, the part can be machined in its entirety on a three-coordinate machine tool, reducing reliance on five-coordinate high-precision equipment on-site, lowering costs, and significantly increasing feed rate and cutting efficiency.

[0035] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of the present invention is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0036] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art, under the guidance of the present invention, can make many other forms without departing from the spirit and scope of protection of the claims, and all such forms are within the protection scope of the present invention.

Claims

1. A method for controlling the deformation of a weakly rigid, ultra-long beam-like structural component for aircraft, characterized in that, The steps are as follows: Step 1: For weakly rigid ultra-long beam structural components, allowances are made in the direction of the two side flanges and the height of the part according to the minimum process allowance requirements; Step 2: According to the minimum process allowance requirements, initially shape the raw material into a square to form a structural component; Step 3: Clamp the structural component with a vise and rough machine the groove on one side in the height direction; Step 4: Rotate the structural component 180° around its length axis, clamp the structural component with a vise, and perform rough machining on the other side of the cavity; Step 5: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine one side of the flange. Step 6: Rotate the structural component 90° around its length axis, clamp the structural component with a pressure plate, and rough machine the other side of the wing surface; At this point, process overlaps naturally form around the structural components; Step 7: After completing the above steps, leave the container to stand still for 24 hours to allow it to naturally age. Step 8: Check the deformation along the entire length of the part, re-square the structural component based on the actual deformation, and correct the structural component datum by removing material. Step 9: Clamp the structural component with a pressure plate and repeat the machining operation in Step 3 to perform fine machining on this side cavity; Step 10: The structural component is rotated 180° around its length axis, and then clamped with a pressure plate to perform precision machining on the other side of the cavity. Step 11: Clamp the structural component with a pressure plate and repeat the machining operation in Step 5 to perform finishing on the theoretical shape of the airfoil; Step 12: Clamp the structural component with a pressure plate and repeat the machining operation in Step 6 to perform finishing on the theoretical shape of the airfoil; Step 13: The fitter removes the process overlap and grinds the cut surface smooth.

2. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 1, characterized in that, In step 1, the minimum process allowance is 5~10mm.

3. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 1, characterized in that, In step 2, the raw material is initially squared to indicate that the cross-section of the raw material is a regular square. The requirements for the perpendicularity and parallelism of the regular square are: less than 1 / 2 of the minimum process allowance.

4. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 1, characterized in that, In steps 3 and 4, allowance of more than 10mm should be reserved during rough machining.

5. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 1, characterized in that, In steps 5 and 6, a 3-5mm allowance is left on the wing surface during rough machining.

6. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 1, characterized in that, In steps 11 and 12, When repeating steps 5 and 6, because the process overlaps at the height of the flange, the clamping force is effectively transferred to the structural component body, the flange has good strength and rigidity, and the surface quality and processing efficiency are not affected.

7. The deformation control processing technology for a weakly rigid ultra-long beam-type structural component for aircraft according to claim 6, characterized in that, In steps 11 and 12, a small tool is used to machine the projected outline of the edge plate in the height direction, and small dimensional allowances are left at equal intervals in some areas to connect with the frame of the process joint.

8. A type of weakly rigid ultra-long beam structure for aircraft, characterized in that, It is processed using the processing technology described in any one of claims 1-7.

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