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The aircraft manufacturing industry faces a severe problem of machining distortion. Machining distortion is caused primarily by residual stresses. The energy conversion during the machining process is the essence of residual stress leading to machining distortion. This paper uses the energy principle to analyze the mechanism of machining distortion of long beam parts, pointing out that during stress redistribution, part of the strain energy is released to do work, and the result of stress redistribution is consistent with the principle of minimum potential energy. The energy concept is used to develop a theoretical model of stress redistribution. A theoretical model of stress redistribution based on the energy principle is proposed. A model is proposed for predicting machining distortion during the machining of long beam-like parts, and the model’s accuracy is demonstrated using a case study.

Prediction of Machining Distortion of Long Beam Monolithic Components Based on the Energy Principle