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<p>As a core component of helicopter transmission systems, the machining quality of aerospace thin-web gears directly determines the overall reliability, operational stability, and service life of the drive system. Owing to their thin-walled structural characteristics, aerospace gears are highly susceptible to machining-induced deformation under cutting loads during processing, leading to deviations in dimensional accuracy and geometric tolerances. Given the significant influence of different turning paths on the distribution of machining-induced residual stress, this study aims to develop a model relay and dynamic mapping of multi-cutting stages simulation method for gear web cutting. Based on the geometric characteristics of the tool-workpiece contact area, the cutting process is deconstructed to establish finite element models for non-free cutting under various machining stages. By employing an improved element birth and death technique and data transmission, high-precision continuous prediction of the entire machining area under different grooving strategies is achieved. Experimental validation confirmed that the model's prediction errors for face runout under the three strategies—axial grooving strategy (AGS), radial grooving strategy (RGS), and bi-directional grooving strategy (BDGS)—were 10.35%, 13.81%, and 15.71%, respectively. Simulation analyses based on this model revealed that workpiece deformation strongly correlates with the distribution gradient of residual machining stresses, but shows a weaker correlation with the magnitude of residual stress. Although the AGS process generated the smallest extreme values of residual stress, it resulted in the largest web deformation due to a higher residual stress distribution gradient. In contrast, the RGS and BDGS strategies significantly suppressed deformation, reducing the maximum web deformation by 64.58% and 79.30%, respectively.</p>

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Modeling and Simulation of Residual Stress and Deformation in Aerospace Thin-Webbed Gear Grooving: A Multistage Cutting Approach with Dynamic Mapping and Model Relay

  • 期刊论文

  • 发表日期：

    2026年7月13日

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  • Guangyue Wang,
  • Jiawei Wang,
  • Wenming Tang,
  • Hao Sun,
  • Lankui Su,
  • Wenyuan Xu,
  • Tao Chen

摘要

As a core component of helicopter transmission systems, the machining quality of aerospace thin-web gears directly determines the overall reliability, operational stability, and service life of the drive system. Owing to their thin-walled structural characteristics, aerospace gears are highly susceptible to machining-induced deformation under cutting loads during processing, leading to deviations in dimensional accuracy and geometric tolerances. Given the significant influence of different turning paths on the distribution of machining-induced residual stress, this study aims to develop a model relay and dynamic mapping of multi-cutting stages simulation method for gear web cutting. Based on the geometric characteristics of the tool-workpiece contact area, the cutting process is deconstructed to establish finite element models for non-free cutting under various machining stages. By employing an improved element birth and death technique and data transmission, high-precision continuous prediction of the entire machining area under different grooving strategies is achieved. Experimental validation confirmed that the model's prediction errors for face runout under the three strategies—axial grooving strategy (AGS), radial grooving strategy (RGS), and bi-directional grooving strategy (BDGS)—were 10.35%, 13.81%, and 15.71%, respectively. Simulation analyses based on this model revealed that workpiece deformation strongly correlates with the distribution gradient of residual machining stresses, but shows a weaker correlation with the magnitude of residual stress. Although the AGS process generated the smallest extreme values of residual stress, it resulted in the largest web deformation due to a higher residual stress distribution gradient. In contrast, the RGS and BDGS strategies significantly suppressed deformation, reducing the maximum web deformation by 64.58% and 79.30%, respectively.