Analysis for Distortion of Thin-wall Milling on Machine Component and its Effect on Global Warming

Hybridizing renewable energy sources improves the reliability of renewable energy system for stand-alone application. However, In order to reduce the weight of aircraft and increase its mechanical performance, more and more large integrated parts are applied in modern aviation industry. The flight power is directly proportional to the weight of the aircraft and rate of fuel consumption, which is equivalent to the released of CO2 into the atmosphere causing more global warming. There is a need for studies on the machining operation of thin-wall components of the airplane. In machining thin-walled aircraft parts, approximately 93% of the materials are removed, resulting in severe distortion of the parts due to the weakened rigidity and the release of residual stress. This might also lead to stress concentration and damage of the parts. The paper presents an outline of the manufacturing solution of thin-walled aluminum alloy Al 7050-T651 for the development of a practical industry solution to optimize part distortion in large thin components in the aerospace industry. The complexity of the process interacts with the need for high dimensional tolerances with excellent mechanical properties of the final piece. This paper proposed and described the development of an analytical model to calculate the final distortion of machined components. With the intention of obtaining data for power model, there have been experimental trials of milling in different parts of an aluminum alloy for aircraft. Finally, the model's ability to predict the final distortion in these work pieces has been validated in comparison to results of distortions specimens obtained in experiments.