Machining deformation of aircraft monolithic component is simulated by finite element method （FEM） and validated by experiment. The initial residual stress in pre-stretched plate is generated by simulating quenching and stretching processes. With a single tool-tooth milling process FEM, the machining loads in monolithic component material removing is obtained. Restart-calculation is put forward to complete the whole simulation of machining process. To verify the FEM result, an experiment is carried out. The deformation distribution of the monolithic component resulting from FEM shows a good agreement with the experiment result, which indicates that the key technologies presented in the paper are practicable and can be used to simulate the milling process of monolithic component to predict its deformation. Lengthy and expensive trial and error experiment process can be avoided.
The tool flank begins to wear out as soon as cutting process proceeds. Cutting parameters such as cutting forces and cutting temperature will vary with increasing degree of flank wear. In order to reveal the relationship between them, the theoretical situations of cutting process were analyzed considering the tool flank wear effect. The variation rules of cutting force, residual stress and temperature distributions along with the tool flank wear were analyzed comparing with the sharp tool tip. Through FEM simulation method, affections of the tool flank wear value VB on cutting forces, residual stress and temperature distributions were analyzed. A special result in this simulation is that the thrust force is more sensitive to tool flank wear, which can be used as a recognition method of tool condition monitoring. The FEM simulation analysis result agrees well with the experimental measuring data in public literatures and some experiments made also by the authors.
