Rodríguez-Sánchez, Alejandro E.
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Rodríguez-Sánchez, Alejandro E.
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Rodríguez-Sánchez, Alejandro Esteban
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Rodríguez-Sánchez, Alejandro E.
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Scopus Author ID
57202719691

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An optimization of part distortion for a structural aircraft wing rib: an industrial workflow approach

2020 , Leonardo Barcenas , Elias Ledesma-Orozco , Sjoerd Van-der-Veen , Francisco Reveles-Arredondo , Rodríguez-Sánchez, Alejandro E.

Inherent residual stresses in the raw material of large monolithic structural components cause distortion when parts are machined. This is a frequent problem in the manufacturing life cycle of aircraft parts that has resulted in recurring concession, rework or scrap, which cost millions of euros to the aerospace industry. In this study an industrial workflow was implemented to predict and optimize part distortion after the machining of a representative structural aircraft-component. This was carried out by means of the following steps: i) characterization of inherent residual stresses of a material using a modified layer removal method; ii) generation of residual stress profiles using part-distortion measurements; and iii) optimization of distortion using Finite Element Analysis to derive an optimal part location. The workflow was validated with three experiments from two aluminum 7050-T7451 specimens with different residual stress states. A prediction of distortion with a Finite Element model resulted in 0.44 mm from the higher residual stresses while from the lower residual stresses the maximum distortion was 0.36 mm. The experimental testing was carried out in a CNC center to validate the numerical results. Good agreement from the numerical results in regards experimental tests led to propose the optimal part location which decreased the distortion up to 0.12 mm.

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Numerical Analysis of Machining Part Distortion in Aircraft Aluminum Structures

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.

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