A new analytical formulation for the dynamics of multipocket thin-walled structures considering the fixture constraints

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DOIResolve DOI: http://doi.org/10.1115/1.4003520
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Journal titleJournal of Manufacturing Science and Engineering, Transactions of the ASME
Article number21014
SubjectAnalytical formulation; Analytical modeling; Computation time; Computationally efficient; Developed model; Finite element models; fixture design; milling; Multi-span plate; Orders of magnitude; Prediction accuracy; Prediction errors; Rayleigh-Ritz methods; Structural component; Thin-walled aerospace structures; Work pieces; Aerospace industry; Computational efficiency; Dynamic models; Dynamic response; Finite element method; Fixtures (tooling); Forecasting; Milling (machining); Thin walled structures; Three dimensional; Structural design
AbstractMilling 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. © 2011 American Society of Mechanical Engineers.
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AffiliationNational Research Council Canada (NRC-CNRC); Aerospace (AERO-AERO)
Peer reviewedYes
NPARC number21271397
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Record identifiera487ca2b-8aa5-427d-a4ec-7ab3cdf5730a
Record created2014-03-24
Record modified2016-05-09
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