Deformation and Chatter Control in Processing and Forming of Thin-walled Curved Titanium Alloy Cover

ZHAO Xiangjie

doi:10.3969/j.issn.1674-6457.2026.09.005

PDF(12710 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (9) : 41-51. DOI: 10.3969/j.issn.1674-6457.2026.09.005

Light Alloy Forming

Deformation and Chatter Control in Processing and Forming of Thin-walled Curved Titanium Alloy Cover

ZHAO Xiangjie

Author information +

History +

Abstract

The work aims to improve the CNC milling accuracy and stability of the TC4 titanium alloy bush body, solve the problems of deformation, stress concentration, and cutting flutter during milling, and develop a process optimization scheme for the milling process system. The core influencing factors of processing defects for titanium alloy casings were analyzed and an inductive analysis was carried out based on the characteristics of titanium alloy hot forming processing; finite element simulation was carried out to study the mechanical response under clamping loads of 10-40 MPa to determine the optimal clamping parameters; an equivalent cutting load of 500 MPa was applied to compare the stress distribution laws at different turning contact points and locate the weak links of the structure; a central ejector pin support scheme was designed and dual-parameter optimization of diameter and preload was completed, and the chatter suppression effect of the scheme was verified through modal analysis and vibration transmission characteristic simulation. The results showed that the clamping pressure was strictly linearly positively correlated with the displacement and stress of the cover. Under a 30 MPa load, both strength safety margin and clamping stiffness were taken into account, which was the optimal clamping parameter; the closer the turning contact point was to the center, the worse the stress condition. The maximum equivalent stress decreased by 20.7% from 7 mm at the center to 28 mm at the outer edge, with the central area being the weak link of cutting; after the optimization of the central ejector pin support, the peak vibration transmission rate decreased from 13.2 to below 1.0, with a peak drop of more than 92.4%, which effectively suppressed cutting chatter. The optimized 30 MPa clamping load and parameter-optimized central ejector pin support scheme can effectively control the deformation and chatter during CNC-milling of titanium alloy covers. The genetic deformation effect induced by pre-process hot-forming blank will affect milling quality, which provides engineering reference for efficient and stable CNC-milling of similar thin-walled parts.

Key words

thin wall surface / milling deformation / titanium alloy cover structure / mechanical properties / vibration control

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

ZHAO Xiangjie. Deformation and Chatter Control in Processing and Forming of Thin-walled Curved Titanium Alloy Cover[J]. Journal of Netshape Forming Engineering. 2026, 18(9): 41-51 https://doi.org/10.3969/j.issn.1674-6457.2026.09.005

References

[1] 都炳智, 胡顺睿, 黄金成, 等. 难加工材料及其薄壁件超声铣削加工研究[J]. 模具工业, 2025, 51(11): 60-68.
DU B Z, HU S R, HUANG J C, et al.Research on Ultrasonic Vibration Milling for Difficult-to-Cut Material and Thin-Walled Part[J]. Die & Mould Industry, 2025, 51(11): 60-68.
[2] 蒲海峰, 袁蕊, 黄泽彪, 等. 薄壁锥体零件新型装夹工艺研究[J]. 中国机械, 2025(32): 64-66.
PU H F, YUAN R, HUANG Z B, et al.Research on New Clamping Technology of Thin-walled Cone Parts[J]. China Machinery, 2025(32): 64-66.
[3] 黄腾, 李建原, 廖路. 薄壁零件微小盲孔精密电加工技术[J]. 机械工程师, 2025(11): 143-146.
HUANG T, LI J Y, LIAO L.Precise Fabrication of Micro-Blind Hole on Thin-Walled Parts by Electrical Discharging Machining[J]. Mechanical Engineer, 2025(11): 143-146.
[4] 赵永彪, 张晓磊, 兰晏文, 等. 基于Mastercam薄壁支架的数控加工研究[J]. 内燃机与配件, 2025(21): 84-87.
ZHAO Y B, ZHANG X L, LAN Y W, et al.Research on CNC Machining of Mastercam Thin Wall Bracket[J]. Internal Combustion Engine & Parts, 2025(21): 84-87.
[5] 刘凯, 韩训梅. 面向薄壁件无颤振铣削的机器人控制策略研究[J]. 机床与液压, 2025, 53(24): 61-68.
LIU K, HAN X M.Research on Robot Control Strategy for Vibration Free Milling of Thin-Walled Parts[J]. Machine Tool & Hydraulics, 2025, 53(24): 61-68.
[6] 周雨, 韩冬, 张学平. 气流封严环加工工艺优化与变形控制研究[J]. 内燃机与配件, 2025(24): 32-34.
ZHOU Y, HAN D, ZHANG X P.Research on Process Development and Machining Optimization of Gas Flow Seal Ring[J]. Internal Combustion Engine & Parts, 2025(24): 32-34.
[7] 贾评家, 黄禹, 王书亭, 等. 薄壁零件的铣削强迫振动预测[J]. 华中科技大学学报(自然科学版), 2025, 53(12): 42-48.
JIA P J, HUANG Y, WANG S T, et al.Forced Vibration Prediction for Milling Thin-Walled Workpiece[J]. Journal of Huazhong University of Science and Technology (Natural Science Edition), 2025, 53(12): 42-48.
[8] 张洣凤, 黄文甫, 吴学意, 等. 薄壁圆柱斜孔加工的夹具设计及加工[J]. 内燃机与配件, 2025(22): 44-47.
ZHANG M F, HUANG W F, WU X Y, et al.Fixture Design and Processing for Thin-Walled Cylindrical Inclined Hole Machining[J]. Internal Combustion Engine & Parts, 2025(22): 44-47.
[9] 鲁淑叶. 基于液胀夹具的薄壁柔轮高精度数控加工工艺研究[J]. 模具技术, 2025(6): 1-7.
LU S Y.High-Precision CNC Machining Technology for Thin-Walled Flexspline Based on Hydraulic Expansion Fixture[J]. Die and Mould Technology, 2025(6): 1-7.
[10] 谢友银. 关于低刚性薄壁件异形夹位的零件加工工艺的探究[J]. 科学技术创新, 2025(22): 102-105.
XIE Y Y.Exploration on the Machining Process of Low Rigidity Thin-Walled Parts with Irregular Clamping Positions[J]. Scientific and Technological InnovationInformation, 2025(22): 102-105.
[11] XUE S Y, QIU T Z, XIAO W L, et al.Interpolation Error Analysis Method for Machining Quality Driven by Toolpath Strategy in Surface Machining[J]. International Journal of Precision Engineering and Manufacturing, 2026, 27(7): 2885-2900.
[12] RADZEVICH S P.Generation of Surfaces: Kinematic Geometry of Surface Machining[M]. 3rd Ed. Boca Raton: CRC Press, 2026.
[13] CIECIELĄG K, WIERTEL M, ZALESKI R. Microstructural Analysis of Glass and Carbon Fiber-Reinforced Epoxy Composites Using Positron Annihilation Lifetime Spectroscopy: Effects of Machining and Temperature[J]. Composites Part A: Applied Science and Manufacturing, 2026, 206: 109810.
[14] MEDIBEW T M, ZIELIŃSKI D, DEJA M. Advances in Material Extrusion-Based Additive Manufacturing of 316L Composite Abrasive Tools for Surface Machining[J]. Manufacturing Letters, 2026, 48: 37-42.
[15] SU P F, WANG W, LIU K Y, et al.Design of a Mixed Robotic Machining System and Its Application in Support Removal from Metal Additive Manufactured Thin- Wall Parts[J]. Robotics and Computer-Integrated Manufacturing, 2025, 92: 102878.
[16] 丁朝臣, 张瑜莹. 薄壁类零组件装配过程仿真与应用[J]. 沈阳航空航天大学学报, 2024, 41(6): 27-41.
DING C C, ZHANG Y Y.Simulation and Application of Assembly Process for Thin-Walled Components[J]. Journal of Shenyang Aerospace University, 2024, 41(6): 27-41.
[17] 刘建伟, 万方前, 李寒荣, 等. 哈氏合金大直径薄壁圆环创新加工方法[J]. 机械研究与应用, 2024, 37(6): 145-147.
LIU J W, WAN F Q, LI H R, et al.Innovative Processing Method of Hastelloy Large Diameter Thin-Walled Ring[J]. Mechanical Research & Application, 2024, 37(6): 145-147.
[18] 宋贺词, 黄树涛, 葛亮, 等. 玻璃纤维增强复合材料薄壁筒端面车削切削力试验研究[J]. 工具技术, 2024, 58(12): 28-36.
SONG H C, HUANG S T, GE L, et al.Experimental Study on Cutting Force in End-Face Turning of Thin-Walled Glass Fiber Reinforced Composite Tubing[J]. Tool Engineering, 2024, 58(12): 28-36.
[19] 汪煦杰, 曹艺, 李春阳, 等. GH188合金薄壁环件切削力研究[J]. 机械制造, 2024, 62(12): 60-62.
WANG X J, CAO Y, LI C Y, et al.Study on Cutting Force of GH188 Alloy Thin-Walled Ring Part[J]. Machinery, 2024, 62(12): 60-62.
[20] 崔浩文, 何恩球, 白俊峰, 等. 离心压缩机薄壁密封加工变形有限元分析[J]. 润滑与密封, 2024, 49(12): 183-189.
CUI H W, HE E Q, BAI J F, et al.Finite Element Analysis of Deformation for Thin Wall Seal in Centrifugal Compressor[J]. Lubrication Engineering, 2024, 49(12): 183-189.
[21] 刘家麟. 铝合金薄壁零件加工变形及工艺优化研究[J]. 产业科技创新, 2024, 6(6): 48-51.
LIU J L.Research on Machining Deformation and Technology Optimization of Aluminum Alloy Thin-Wall Parts[J]. Industrial Technology Innovation, 2024, 6(6): 48-51.
[22] 张胜, 袁超. 奥氏体不锈钢薄板的钻孔加工工艺改进[J]. 金属加工(冷加工), 2024(12): 49-53.
ZHANG S, YUAN C.Improvement of Drilling Processing Technology for Austenitic Stainless Steel Thin Plate[J]. Metal Working (Metal Cutting), 2024(12): 49-53.
[23] 胡伟康, 刘焕牢, 何优. 医用TPU薄壁微管的挤出工艺参数优化[J]. 塑料工业, 2024, 52(11): 78-84.
HU W K, LIU H L, HE Y.Optimization of Extrusion Process Parameters for Medical TPU Thin-Walled Microtubes[J]. China Plastics Industry, 2024, 52(11): 78-84.
[24] 梁锐, 钟燕春, 符锡成. 复杂薄壁配合件加工及其夹具改进[J]. 机电工程技术, 2024, 53(11): 176-181.
LIANG R, ZHONG Y C, FU X C.Processing of Complex Thin-Walled Mating Parts and Improvement of Fixtures[J]. Mechanical & Electrical Engineering Technology, 2024, 53(11): 176-181.
[25] 杨廷杰, 任冬雪, 程敏, 等. 聚丙烯薄壁注塑制品白色条带现象解析[J]. 塑料工业, 2024, 52(11): 122-128.
YANG T J, REN D X, CHENG M, et al.Analysis of White Stripe Phenomenon of Polypropylene Thin- Walled Injection Molded Products[J]. China Plastics Industry, 2024, 52(11): 122-128.
[26] 丁云鹏, 岳彩旭, 单鑫鑫, 等. 基于变形有限元仿真的薄壁套筒加工参数优选[J]. 制造技术与机床, 2020(6): 108-110.
DING Y P, YUE C X, SHAN X X, et al.Thin-Wall Cylinder Processing Parameter Optimization Based on Deformation Simulation of Thin-Wall Liner[J]. Manufacturing Technology & Machine Tool, 2020(6): 108-110.

Funding

Scientific Research Program of Xi'an Aeronautical Polytechnic Institute (2024) (24XHZK01); The 2023 Youth Innovation Team of Shaanxi Universities (2023-98)