# The Influence of Wide-Directional Asymmetric Spraying on Machining Deformation of Aluminum Alloy Plates

## TL;DR

This study examines how asymmetric residual stresses and machining strategies affect deformation in aluminum alloy plates used in aerospace components.

## Contribution

The study introduces a method to reduce machining deformation by optimizing residual stress states and diagonal milling sequences.

## Key findings

- Lower initial stress asymmetry leads to less deformation in aluminum alloy plates.
- Diagonal milling reduces deformation by up to 4% compared to other strategies.
- Optimizing stress release during machining significantly improves precision in aerospace manufacturing.

## Abstract

This study investigates the machining deformation of thick aluminum alloy plates, specifically in aerospace frame components, focusing on the influence of asymmetric residual stress states and machining strategies. Aluminum alloys are commonly used for large structural components due to their strength, formability, and corrosion resistance. However, machining these components often leads to deformation caused by residual stress release, cutting forces, and thermal effects. Using finite element simulations and experimental validation, the study analyzes how asymmetric residual stresses, induced by spray quenching, affect deformation patterns during machining. It is found that lower initial stress asymmetry results in less deformation, while machining sequences that optimize stress release significantly reduce the final distortion. Among the strategies tested, the diagonal milling sequence yielded the smallest deformation, achieving a reduction of up to 4%. The study concludes that both the initial residual stress state and the machining strategy are critical in controlling deformation, offering insights for improving machining processes in aerospace manufacturing to enhance precision and reliability.