Resumen de Fast simulation - assisted shape correction after machining
Ramiro Mena Andrade
Distortions after machining of large aluminium forgings are a recurrent problem for the aeronautical industry. These deviations from design geometry are caused by the presence of residual stresses, which are developed along the manufacturing chain, especially after the heat treatment of quenching. To solve this problem, a series of post-machining operations called reshaping are required. Despite reshaping manages to restore the correct geometry, it is highly manual and time consuming, therefore, there is a need at an industrial level to use numerical simulation to study reshaping.
The aim of this thesis is to explore the use of novel numerical techniques, especially Model Order Reduction (MOR), to study the problem of distortion and the operations required to mitigate these geometrical defects. The document starts with a review of the open problem of distortions, explains the available techniques used at Airbus to repair the structural parts and describes, from a numerical point of view, the challenges to study reshaping. Then, focusing on the operation of bending straightening, reshaping is simulated first by using a simplification hypothesis and afterward, by applying the MOR technique called Sparse Subspace Learning (SSL). Thanks to this powerful tool, it is possible to reconstruct the solution space (e.g. displacements) in a non-intrusive way and to find the optimum configuration to minimize distortion in real time before launching the actual operation.
