Large and thick aeronautical structural parts frequently exhibit significant distortions after machining because of the residual stresses due to previous steps (heat treatment). A Post- machining shape correction phase, based on successive mechanical operations (for example, 3-point bending) has to be applied. This process is long and costly and cannot be standardized because distortions vary from one part to the other (non reproducibility). The reshaping process relies entirely on the know-how and experience of the operator.

There is a need to introduce numerical simulation in order to assist the operator and propose the optimal shape correction sequence.
The aim of this project is to demonstrate the feasibility of such an approach. Two challenging issues have to be tackled:

  • The building of a Reduced Order Model able to reproduce the results of the thermo- mechanical simulation (heat treatment, machining, reshaping).
  • The identification of the uncertain parameters (material properties, boundary conditions), using the ROM, through the comparison of the response of the real part to the few 1st reshaping operations with the predicted behaviour.

A virtual demonstration of this approach will be performed where the “real” part will be a simulation, which uncertain parameters will be supposed not to be known.


PhD candidate: Ramiro Mena (Airbus, École Centrale de Nantes, Universitat Politècnica de Catalunya)

Academic supervisors: Prof. F. Chinesta, Dr. J.V. Aguado (ECN), Prof. A. Huerta (UPC)

Industrial supervisor: Dr. S. Guinard (Airbus)