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This publication is a result of the project entitled “Development of the milling technique of thin-walled integral elements made of aviation light metal alloys in the context of minimalisation post-machining deformations”, contract number: LIDER14/0153/2023, total project value: 1,543,750.00 PLN. The project is financed by the National Centre for Research and Development under the 14th edition of the LIDER Programme.
Modern aircraft must meet stringent requirements related to, among other things, reducing the weight of their compo-
nents whilst maintaining high strength and accuracy. Thin-walled integral elements are therefore widely used in aircraft
structures. In industrial practice, however, their application poses a significant problem due to the susceptibility of these
components to deformation, especially post-machining deformation, which becomes evident once the machining process
is completed and the clamping force is removed. This is a very complex issue, and finding a comprehensive solution is
complicated because of a large number of factors affecting the formation of post-machining deformation. This study inves-
tigates machining strategies in terms of post-machining deformation of thin-walled parts. Relationships are established
between the residual stress in the surface layer of the material and the dimensional and shape accuracy of a thin-walled
component made of aluminium alloys 2024 T351 and 7050 T7451. The machining strategies used in this study were the
“Christmas tree” strategy and the hybrid strategy (combination of the “Christmas tree” strategy and milling of one side of
the wall with constant axial and radial depths of cut). The cutting speed was also analysed. The results demonstrate that
the post-machining deformation of thin-walled parts can be minimized by using a suitable machining strategy. An impor-
tant finding is that it is possible to impact the residual stress in the surface layer of the material through milling strategy
and cutting speed, leading to enhanced dimensional and shape accuracy of the thin-walled component. Better machining
results in aspect of wall strain were obtained for the 7050 T7451 alloy.
