Optimization on initial configuration of monolithic component for machining deformation control

The machining of monolithic components is prone to deformation, which causes a large amount of production resources to be wasted. Therefore, studying the process of initial configuration optimization method to reduce machining deformation is of great significance for the precision machining of monolithic components. In this paper, the concept and mathematical expression of the initial process configuration are proposed for aluminum alloy U-shaped cross-section stringer structural components. The initial configuration optimization problem is formulated with the initial process configuration as the variable and the objective of minimizing machining deformation. An iterative method is used to optimize the initial process configuration. The machining deformation after the optimized configuration was analyzed by finite element simulation and theoretical calculation, and the deformation data error of the two was less than 20%, which verified the correctness of the method proposed in this paper. Machining tests were carried out, and the results show that the proposed initial configuration optimization method can control the deformation of the U-shaped long truss parts within ± 0.06 mm/m, which is 80–90% less than that before optimization. This initial configuration optimization method has a positive effect on controlling machining deformation.