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    Item type:Publication,
    Numerical Analysis of Machining Part Distortion in Aircraft Aluminum Structures
    (ASME, 2020)
    Ledesma-Orozco, Elías
    ;
    Rodríguez-Sánchez, Alejandro E.  
    The inherent residual stresses in the raw materials of large monolithic structural components whereby machining procedures are needed to produce aircraft components, cause deviations, and distortions that are undesired and rise challenges for engineering design and engineering production teams of the aerospace companies. A numerical approach to address part distortion is proposed in this paper. An algorithm was developed and implemented as a finite element subroutine in the software ANSYS APDL, which uses the raw inherent residual stress parameters of the aluminum alloy and the machining locations of a structural specimen to simulate the machining distortion phenomenon in aircraft aluminum structures. This algorithm uses as inputs the finite element mesh of a component, the coefficients of residual stresses functions, and the machining location parameters from where a part is made of a raw material blank. The numerical results predicted the part distortion phenomenon with an Absolute Error of 2.79% with respect to initial experimental measurements of part distortion. Additionally, the proposed approach was used to develop part distortion curves by considering the machining location of the specimen. From these, numerical optimization techniques led to determine the machining location of the representative specimen that attained lower distortions. Such location corresponded to a vertical value around of 3.15 mm for the two simulated residual stresses conditions in the material. An additional measurement was carried out to validate the optimal numerical results and errors below 3% were obtained. Consequently, the proposed approach can be of use to determine, to reduce and to optimize part distortion without further experimental testing in structural aluminum 7050-T7451 alloy aircraft components.
      14  1
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    Solidification and Solid-State Transformations of Metals and Alloys
    (Elsevier Inc., 2017)
    Quintana, María José
    ;
    Pero-Sanz, José Antonio
    ;
    Verdeja González, Luis Felipe
    Solidification and Solid-State Transformations of Metals and Alloys describes solidification and the industrial problems presented when manufacturing structural parts by casting, or semi-products for forging, in order to obtain large, flat or specifically shaped parts. Solidification follows the nucleation and growth model, which will also be applied in solid-state transformations, such as those taking place because of changes in solubility and allotropy or changes produced by recrystallization. It also explains the heat treatments that, through controlled heating, holding and cooling, allow the metals to have specific structures and properties. It also describes the correct interpretation of phase diagrams so the reader can comprehend the behaviour of iron, aluminium, copper, lead, tin, nickel, titanium, etc. and the alloys between them or with other metallic or metalloid elements. This book can be used by graduate and undergraduate students, as well as physicists, chemists and engineers who wish to study the subject of Metallic Materials and Physical Metallurgy, specifically industrial applications where casting of metals and alloys, as well as heat treatments are relevant to the quality assurance of manufacturing processes. It will be especially useful for readers with little to no knowledge on the subject, and who are looking for a book that addresses the fundamentals of manufacturing, treatment and properties of metals and alloys. Uses theoretical formulas to obtain realistic data from industrial operations. Includes detailed explanations of chemical, physical and thermodynamic phenomena to allow for a more accessible approach that will appeal to a wider audience. Utilizes micrographs to illustrate and demonstrate different solidification and transformation processes. © 2017 Elsevier Inc. All rights reserved.
      13  1