A part deformation control method via active pre-deformation based on online monitoring data

Pre-deformation of the workpiece in the elastic range is an effective deformation control method, as the machining deformation can be balanced by the pre-deformation. Different from the traditional pre-deformation control method based on experience or inaccurate prediction before machining, an innovative idea of online active pre-deformation control based on deformation monitoring data is proposed in this paper. The deformation monitoring data are used to analyze the workpiece state and predict the deformation of the next layer based on a cubic spline curve fitting approach, and then Kalman filter algorithm is used to control the error between the prediction deformation and the actual deformation so as to ensure the pre-deformation control accuracy. A real aircraft structural part is used to validate the proposed method, and the results show that the part deformation can be significantly reduced.