Due to the rapid development of the aviation industry, modern aircraft components have higher performance requirements, with a particular emphasis on lightweighting and high strength. Reducing aircraft structural weight improves maneuverability, payload capacity, and range, while increasing structural strength also extends the aircraft’s service life. Consequently, aircraft component design and manufacturing must meet more stringent functional and material performance requirements.
1 Characteristics of aviation parts
Aviation parts have the following characteristics
(1)The bolts in standard parts generally use high-strength bolts without locking plates.
(2)The adjusting piece and sealing structure of the zoom and vector nozzles have high requirements for processing technology due to their precise structure, thin wall, weak material cutting ability, easy deformation.
(3)Graphite sealing structures and brush sealing structures are increasingly used in modern aircraft engines, replacing traditional grate seals, honeycomb seals and bellows seals.
（4）The actuator has multiple execution and adjustment functions, a more complex structure, more stringent requirements on structural accuracy and hydraulic performance, and higher requirements on manufacturing process and testing technology.
（5）The oil pipe nozzle has two major functions: nozzle spraying and control adjustment. It has a complex structure and has strict requirements on structural accuracy and hydraulic performance. It requires corresponding processing technology and testing technology to meet the functional requirements.
Integrated structural design, an advanced manufacturing technology, has been widely adopted in aviation parts. It significantly reduces the number of parts and structural weight, increasing performance and reliability by dozens of times. However, during CNC machining, parts are prone to complex deformations such as bending and torsion due to initial residual stress, structural unevenness, and process defects. Thin-walled parts are particularly prone to structural instability, which seriously affects manufacturing efficiency and product precision.
2 Analysis of factors affecting deformation of aviation parts machining
During the machining process, aviation parts are affected by factors such as residual stress, cutting force, and machining vibration. Machining deformation is not only related to these factors, but also to process conditions, part structure, and process system. Therefore, it is necessary to control these major factors that affect machining deformation in order to effectively control it.
3 Deformation control methods for aviation parts machining
Deformation control during machining of aviation parts is primarily divided into early prevention and post-process correction. Early control reduces deformation by optimizing process conditions (such as adjusting the machining sequence and removing residual stress), while post-process correction corrects deformed parts using methods such as shot peening and laser heat treatment.
4.Aviation Parts Machining Deformation Simulation Technology
In recent years, in order to reduce the impact of milling on the deformation of aviation parts during machining, researchers have used finite element simulation technology to predict the deformation of parts.
The initial residual stress of a part is the main cause of its deformation after machining. To accurately simulate deformation during machining, it is usually necessary to use finite element software such as ANSYS APDL to establish a residual stress model and perform numerical simulation to guide actual machining.
In finite element simulation, key technical difficulties such as initial residual stress, modeling, material removal, and constraint transfer limit its application. In order to improve the processing efficiency and stability of aviation parts, it is necessary to develop more efficient methods to predict and control deformation.
5 Conclusion
Due to factors such as residual stress and cutting forces, aviation parts are prone to deformation during milling. While correction can be achieved through post-processing, this approach is time-consuming and costly. Therefore, early control is the primary means of preventing part deformation, and the continuous development of machining deformation simulation technology will be key to achieving high-precision machining.