Milling of thin-walled aerospace structures is a critical process due to the high flexibility of the workpiece. Current practices in the fixture design and the choice of cutting parameters rely solely on conservative guidelines and the designer’s experience. This is a result of the lack of computationally efficient dynamic models to represent the dynamic response of the workpiece during machining, and the interaction between the workpiece, fixture and the cutting forces. This paper presents a novel dynamic formulation of typical thin-walled pockets encountered in aerospace structures. It is based on an analytical description of a five-sided pocket using a plate model. An off-line calibration of the model parameters, using global and local optimization, is performed in order to match the dynamic response of the pocket structure. The developed simplified model is based on Rayleigh’s energy method. Various pocket shapes are examined under different loading conditions and compared to finite element (FE) predictions and experimental results. In both cases, the results obtained by the developed model are in excellent agreement. This proposed approach resulted in one to two orders of magnitude reduction in computational time when compared to FE models, with a prediction error less than 10%.
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e-mail: mouhab.meshreki@nrc.ca
e-mail: jozsef.kovecses@mcgill.ca
e-mail: helmi.attia@nrc.ca
e-mail: nejah.tounsi@nrc.ca
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June 2008
Research Papers
Dynamics Modeling and Analysis of Thin-Walled Aerospace Structures for Fixture Design in Multiaxis Milling
Mouhab Meshreki,
Mouhab Meshreki
Aerospace Manufacturing Technology Center, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada; Department of Mechanical Engineering,
e-mail: mouhab.meshreki@nrc.ca
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6, Canada
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József Kövecses,
József Kövecses
Department of Mechanical Engineering and Centre for Intelligent Machines,
e-mail: jozsef.kovecses@mcgill.ca
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6, Canada
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Helmi Attia,
Helmi Attia
Fellow ASME
Aerospace Manufacturing Technology Center, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada; Department of Mechanical Engineering,
e-mail: helmi.attia@nrc.ca
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6m Canada
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Nejah Tounsi
Nejah Tounsi
Aerospace Manufacturing Technology Center,
e-mail: nejah.tounsi@nrc.ca
National Research Council Canada
, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada
Search for other works by this author on:
Mouhab Meshreki
Aerospace Manufacturing Technology Center, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada; Department of Mechanical Engineering,
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6, Canadae-mail: mouhab.meshreki@nrc.ca
József Kövecses
Department of Mechanical Engineering and Centre for Intelligent Machines,
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6, Canadae-mail: jozsef.kovecses@mcgill.ca
Helmi Attia
Fellow ASME
Aerospace Manufacturing Technology Center, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada; Department of Mechanical Engineering,
McGill University
, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6m Canadae-mail: helmi.attia@nrc.ca
Nejah Tounsi
Aerospace Manufacturing Technology Center,
National Research Council Canada
, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canadae-mail: nejah.tounsi@nrc.ca
J. Manuf. Sci. Eng. Jun 2008, 130(3): 031011 (12 pages)
Published Online: May 16, 2008
Article history
Received:
December 18, 2006
Revised:
January 23, 2008
Published:
May 16, 2008
Citation
Meshreki, M., Kövecses, J., Attia, H., and Tounsi, N. (May 16, 2008). "Dynamics Modeling and Analysis of Thin-Walled Aerospace Structures for Fixture Design in Multiaxis Milling." ASME. J. Manuf. Sci. Eng. June 2008; 130(3): 031011. https://doi.org/10.1115/1.2927444
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