Reducing part distortion: Research & Innovation

Part distortion is a major cost factor in the production of metallic parts, especially in the case of large and thin-walled workpieces that play an important role in lightweight design or in aerospace.

Along with partners, Fraunhofer Institute for Production Technology in Aachen, Germany, has developed a system for reducing part distortion caused by residual stresses. With a model-based process design and a new type of clamping system, companies will be able to significantly reduce part distortion when milling in the future.

During production and subsequent heat treatment of metallic blanks, residual stresses are generated, which lead to shape and dimensional deviations of workpieces while machining. Particularly after unclamping, when a workpiece is released from the clamping system, substantial distortion of the part occurs. Part distortion of this kind means that the manufacturing tolerances cannot be maintained and the part has to be reworked.

For the VoKoES research project, the team developed simulation software and a new type of clamping system that can be used to predict and reduce part distortion during milling. Image courtesy of Fraunhofer Institute for Production Technology