An analytical machining deformation model of H-section multi-frame beam integral components

More attention has been paid to the deformation prediction and control of multi-frame components, in which the residual stress is the main factor affecting the deformation. Based on the equivalent bending stiffness theory, the analytical prediction model of machining deformation considering initial residual stress was established. Based on the theory of plate and shell, the influence of stress redistribution and stress balance on the deformation is studied during process of the material removal. And the functional relationship between them is established to analyze the influence of the incline of neutral layer and deformation. On this basis, the time-varying section moment of inertia equation of workpiece in the process of material removal is developed, the deformation prediction method of U-section structural parts is proposed, and the deformation prediction model of H-section beam frame parts is extended. The correctness of the proposed model is verified by experiments and finite element simulation. Finally, the effects of different processing techniques on deformation are analyzed by finite element and experimental methods. At the same time, the effects of two processing environments (dry and wet processing) on the surface roughness of the workpiece are compared. The results show that the average deformation of the method of layer removal was reduced by 65.8%, and the surface roughness of the wet processing was increased by 72.8%. It provides theoretical calculation support for deformation prediction of complex structure workpiece.