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Research Papers

A New Analytical Formulation for the Dynamics of Multipocket Thin-Walled Structures Considering the Fixture Constraints

[+] Author and Article Information
Mouhab Meshreki

Aerospace Manufacturing Technology Centre, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canadamouhab.meshreki@cnrc-nrc.gc.ca

Helmi Attia

Aerospace Manufacturing Technology Centre, National Research Council Canada, 5145 Decelles Avenue, Montreal, QC, H3T 2B2, Canada; Department of Mechanical Engineering, McGill University, Montreal, QC H3A 2K6, Canadahelmi.attia@cnrc-nrc.gc.ca

József Kövecses

Department of Mechanical Engineering and Centre for Intelligent Machines, McGill University, 817 Sherbrooke Street West, Montreal, QC, H3A 2K6,Canadajozsef.kovecses@mcgill.ca

J. Manuf. Sci. Eng 133(2), 021014 (Mar 25, 2011) (14 pages) doi:10.1115/1.4003520 History: Received October 19, 2009; Revised January 19, 2011; Published March 25, 2011; Online March 25, 2011

Milling of thin-walled aerospace structures is a critical and challenging process. Available models for the prediction of the effect of the fixture on the dynamic response of flexible workpieces are computationally demanding and fail to represent practical cases for milling of thin-walled structures. Based on the analysis of typical structural components encountered in the aerospace industry, a generalized unit-element, with the shape of an asymmetric pocket, was identified to represent the dynamic response of these components. Accordingly, a computationally efficient dynamic model was developed to predict the dynamic response of typical thin-walled aerospace structures using the Rayleigh–Ritz method. In the formulation of this model, the dynamics of a 3D pocket is represented by an equivalent 2D multispan plate taking into account the effect of deformable fixture supports. The developed model was validated numerically and experimentally for different workpiece geometries and various types of loading. This model resulted in one to two orders of magnitude reduction in computation time when compared with the finite element models, with prediction errors less than 10%. The developed model meets the conflicting requirements of prediction accuracy and computational efficiency needed for interactive fixture design.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 14

Displacement response results when milling a thin-walled pocket without supports

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Figure 15

Displacement response results when milling a thin-walled pocket without supports

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Figure 7

Comparison of the responses of pocket 6 predicted by the FE and the MSP models

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Figure 5

Representation of the dimensions of the generalized pocket used for the validation of the MSP model

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Figure 4

Representation of a multispan plate

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Figure 3

Illustration for the representation of a pocket with a multispan plate

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Figure 2

Illustration of the dimensions in millimeter of the pockets used to evaluate the effect of adjacent pockets

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Figure 1

Different cases for the unit-element (pocket) in structural aerospace components

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Figure 13

Illustration of the setup during the machining of sides 1 and 3

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Figure 12

Dimensions of the rectangular pocket in millimeter

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Figure 11

Comparison of the responses from experiment, FE model, and MSP model

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Figure 10

Comparison of the response of the pocket with internal rib-wall predicted by the FE model and the MSP model with the FSS formulation

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Figure 9

Dimensions in millimeter of the pocket with internal rib-walls

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Figure 8

Comparison of the responses of pocket 6 with two supports predicted by the FE model and the MSP model with the FSS formulation

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Figure 6

Comparison of the responses of pocket 1 predicted by the FE and the MSP models

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