The machining of aircraft structural components is a major component of aircraft manufacturing engineering. In the past, large structural parts of aircraft were often assembled from many parts. In recent years, the overall design principle of aircraft structural parts has received more and more attention. The basic concept of the overall design is to cut the metal from a single blank to obtain a monolithic structural part with superior performance. Its advantages are not only shortened the processing assembly cycle and logistics chain, but also reduce the weight of structural parts, which is very important for modern passenger aircraft and fighter aircraft.
Aircraft structural components include fuselage, wings, bulkheads and ribs, most of which are thin-plate parts with numerous complex holes, cavities, grooves and stiffeners, as shown in Figure 1. The material is mainly high-strength aluminum alloy, and the blank is an aluminum plate or aluminum ingot of 60-300 mm thick, and the length is 1-30 m.
The commonality of the whole structural parts processing is that the metal removal rate of the blank is above 80%, and even up to 95% for the new type of fighter. Due to the extensive use of 3D CAD and finite element analysis in the design of aircraft structural parts, the structure is continuously optimized, and the material properties are fully utilized, so that it is possible to significantly reduce the weight while increasing the strength of the structural member. This inevitably leads to a complicated structure, a large number of holes, and a thin wall thickness, which must be processed using a 5-axis CNC machine tool.
After further analyzing the processing technology of modern aircraft structural parts, the following requirements are generally proposed for the new generation of CNC machine tools:
(1) The machining efficiency of the machine tool is high, the metal removal amount is large, and the spindle can provide sufficient power for high-speed milling.
(2) The machine tool has high precision and reliability, stable performance, and can guarantee the processing quality without relying on the inspection process after processing.
(3) Process intensification, all processes are completed as much as possible on one machine tool, and the tool magazine capacity is more than 100 tools.
(4) Convenient loading and unloading of workpieces, low operating cost, less environmental pollution, friendly man-machine interface, and long-distance operation and monitoring.
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