The use of new types of technological equipment in non-rigid plane aluminum parts production using wave techniques

Abstract

It has been suggested that wave technologies in non-rigid plane parts production should be used with the introduction of ultrasonic range vibrations into the shaping zone in combination with technological equipment, i.e. it is- a zero-base system. The traditional technique used in domestic enterprises implies a high probability of out-of-flat conditions and deformations due to the influence of technological residual stresses (TRS) in the process of stock removal or force stresses under plastic deformation of the part when fixing blanks. Using modern universal software systems such as Simulia Abaqus, ANSYS, etc., it was possible to determine the magnitude of deformations, aligment errors caused by residual stresses. The data obtained were used to calculate rational ways for fixing some typical non-rigid plane aluminum blanks on a technological equipment - a zero-based system of German production SCHUNKVERO–SAviation (VSA). The research was aimed at determining the manufacturability for the use of such equipment when making a particular non-rigid blank made of aluminum alloys and finding the most optimal way of its fixing. The estimated values of the TRS were determined by mechanical and X-ray methods. The calculations were performed using real parts of aircraft equipment of the "beam" type and blanks made of aluminum rolled products. The proposed method for determining the maximum amount of deformation of the workpiece under machining is applicable to the most optimal placement of the support and clamping modules of the zero-based system (VSA). In combination with a certain strategy of wave mechanical processing, it makes a practically complete compensation for deformations possible and allows obtaining a suitable product from the first presentation without performing an additional correction operation.