Arc Flange and Web Machining Without Setup Changes
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Solution Overview
Problem
Conventional machining methods for aircraft components with complex surface shapes, such as chemical milling, face challenges in reducing environmental load and energy usage, and struggle to perform plate thinning machining on multiple surfaces without causing distortion across surfaces.
Innovation Solution
A machining method using a jig with a supporting surface and contacting surfaces to press and cut flange and web parts with a tool having end and peripheral cutting edges, allowing for arc-direction feeding to perform plate thinning machining on multiple surfaces without setup changes, while controlling the tool's attitude to match the surface distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If chemical milling is used for plate thinning machining, then weight reduction is achieved, but environmental load increases and waste liquid treatment becomes necessary
Solution Approach 1:
The patent replaces chemical milling with mechanical cutting using a CNC machining center. The cutting tool mechanically removes material through controlled cutting forces, achieving plate thinning without chemical reactions. This substitution eliminates the need for chemical solutions, waste liquid treatment, and associated environmental hazards while maintaining weight reduction benefits.
2Object-affected harmful factors
If mechanical working is used for plate thinning machining, then environmental load is reduced, but distortion occurs on other surfaces when machining multiple surfaces
Solution Approach 1:
The patent divides the complex curved surface into multiple measurement sections along the longitudinal direction. Each section is independently measured and analyzed for its specific distortion characteristics. This segmentation allows the machining process to address each surface section's distortion separately, preventing mutual interference and maintaining precision across all surfaces during mechanical cutting.
Solution Approach 2:
The patent dynamically adjusts machining parameters including tool attitude angles, cutting speeds, and feed rates based on the measured distortion characteristics of each surface section. By changing these parameters according to local surface conditions, the process compensates for distortion tendencies and maintains manufacturing precision across multiple surfaces without causing additional deformation.
3Manufacturing precision
If set-up change is performed for machining each surface, then machining precision can be maintained, but productivity decreases
Solution Approach 1:
The patent develops a universal machining strategy that can handle multiple surfaces of the workpiece without requiring set-up changes. The CNC machining center is programmed to access and machine different surfaces through coordinated tool movements and attitude adjustments. This multi-functional approach allows all surfaces to be machined in a single set-up, eliminating time-consuming repositioning operations while maintaining precision through controlled tool orientation and path planning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient plate thinning machining on multiple surfaces without setup changes, reducing distortion and stress concentration, and achieving precise cutting with a machined product having varying cutter mark pitches, thus enhancing machining precision and reducing manual finishing needs.
Implementation Method 1
a flange cutting step of cutting the flange part by the peripheral cutting edge of the tool by feeding the tool in an arc direction of the arc shape
Implementation Method 2
a web cutting step of cutting the web part by the end cutting edge of the tool by feeding the tool in the arc direction
Data Source
AI summary
The machining method uses a tool to machine a workpiece set in a jig, the workpiece has a plate-like web part arc-shaped in plan view and a flange part bent and arranged vertically from an edge along the arc shape, the tool has an end cutting edge and a peripheral cutting edge, and the jig has a surface where the web part is placed and a contacting surface where the flange part comes into surface contact. The machining method includes: pressing the flange part against the contacting surface; cutting the flange part by the peripheral cutting edge by feeding the tool in an arc direction of the arc shape; and cutting the web part by the end cutting edge by feeding the tool in the arc direction.