Accurate prediction of cutting process parameters is very important for achieving high-efficiency and chatter-free milling process. In this paper, the methods, principles, simulation algorithms and engineering applications of dynamic modeling for milling process are reviewed. First of all, the modeling methods of cutting process are classified into four categories: empirical method, analytical method, FEA method and mechanical method. And its characteristics are analyzed. Secondly, the static cutting force model and dynamic cutting force model are introduced in detail, and their respective application occasions are given. Thirdly, the principles, advantages and disadvantages, and applicatio conditions of several typical stability analysis of milling process are compared, which can be used as theoretical basis for selecting suitable stability analysis method. Lastly, two common used surface topography prediction methods for milling process are introduced. Conclusions of above-mentioned analysis can be used as theoretical guidance for further researches or engineering applications in the field.

      Based on the elastic-plastic forming theory and Finite Element Method (FEM), a numerical model is established to investigate the forming of spatial tubes in spatial tube bending-twisting process. Investigations are focused on three aspects, including the forming principles of spatial tubes under combined bending and twisting, the variations of forming parameters under different eccentricities of fixed die and the non-linear relationship between the eccentricities of fixed die and the torsion adjustment indexes. The conclusions are: (1) In spatial tubes bending-twisting process, the real bending radius can be influenced by the rotation angles of mobile die and clamp. (2) The equivalent bending points acquired from pure bending are not suitable for spatial tube bending, due to the fact that the torsion adjustment index at equivalent bending point can be influenced by other factors (eccentricity of fixed die, clamp rotation speed, etc). (3) If the twisting angle keeps constant, the torsion adjustment index will increase accordingly with the increasing of clamp rotation speed, and decrease with the increasing of eccentricity of fixed die.

      Panel mold has the characteristics of complex shape, high hardness and multi hardness stitching. In the process of machining, the tool load is unstable, the tool temperature is too high and the cutting tool is easily worn out. Thus the surface quality of the die and the service life of the tool are reduced. In order to reveal the milling mechanism, a threedimensional finite element simulation model for the milling process of convex surface splicing dies was established and the 3D finite element simulation method is used to study the milling process of the convex surface splicing die. First, the constitutive parameters of the material are fitted by the quasi static test and the Hopkinson pressure bar test to ensure the accuracy of the simulation results. Secondly, a three-dimensional thermal coupling simulation model of the convex surface splicing die milling process is established. Finally, the changing characteristics of force and temperature during the milling process of the convex surface splicing die are studied through simulation results. The research results provide theoretical support for mold of aerospace products milling technology and tool structure design.

      The traditional manufacturing equipment is hard to meet the demand of high-speed, high-precision and high-flexible machining, Research and development of high-performance processing equipment is imperative. In order to achieve the goal of high-speed and high-precision machining, a 5-axis hybrid robot for milling operation is proposed. A brief introduction of the robot and its kinematic analysis are presented. To improve the machining accuracy, the principle of parametric curve interpolation and its application in the hybrid robot are studied. Finally, taking the helical milling of holes as an example, the experiment of milling holes on titanium alloy is carried out. Simulation and experimental results show that the parametric curve interpolation method can effectively limit the feedrate fluctuation and improve the machining accuracy. In the end, it is pointed out that the hybrid robot has the characteristics of high-rigidity, high-speed, high-precision and high-flexibility, and it has broad application prospects in the aviation manufacturing industry.

      For virtual simulation demand of three dimensional sheet metal pieces laser cutting and the shortcomings of the current laser cutting process simulation system, with gantry five-axis machine tools, vertical axis robot and upsidedown six-axis robot cutting platform as sample, multi-platform three-dimensional sheet metal laser cutting process simulation system, including virtual machining scene 3D visualization, machine kinematics calculation based on site data, laser cutting technology and processing code output is developed. Configuring node sequence to realize virtual machining scene construction, based on Nurbs surface fitting, this paper realizes the mapping of the cutter site data with the shape of nonvertical sidewall cutting. Based on the cutter point data, the laser head pose matrix is solved, and the D-H motion coordinate system is established to realize the kinematics calculation of the machine tool and the simulation of machine tool motion. The process of cutting process is established, and the cutting process is realized, including the embodiment of cutting process defect, the detection and processing of interference collision, and the display of the transition trajectory between the cutting ring. Finally, corresponding reliable platform processing code is output.

      With the complication of the three-dimensional geometry of the aerial tube and the increasing requirements of the manufacturing precision, the application of the finite element analysis method to study the optimum bending process has become a universal choice. In this paper, the forming principle of typical tube bending forming process is studied, and the evaluation index of tube bending performance is analyzed. To improve the efficiency and reduce the difficulty of using the finite element analysis in the tube bending, the user defined interface of the bending tube forming based on the ABAQUS general finite element analysis software platform is developed by using the Python programming language. It provides both preprocessing and post-processing functions of the rotary draw bending and free tube bending. By analyzing the finite element analysis results of tube bending, it can automatically calculate the evaluation index of tube bending and produce the analysis report.

      Based on the macro-micro unified constitutive equation of stress relaxation of 2219 aluminium alloy, the user subroutine was redeveloped and compiled into nonlinear finite element analysis software MSC. Marc. The simulation model of the stress-relaxation aging forming process of the 2219 aluminum alloy tank cover was established and the stress-strain and mechanical property evolution of the stress-relaxation aging forming process of the cover were analyzed. The optimization design of the mold surface based on springback compensation analysis is performed, and the mold profile that meets the requirements of the forming target is determined. The stress relaxation aging forming experiment of 2219 aluminum alloy was carried out. The results of experiment and simulation were analyzed. The results show that the experiment results of stress relaxation aging forming agree well with the results of finite element simulation. The relative deviation of the forming surface radiuses between experiment and simulation is 0.22%, and the relative deviation in the yield strength is 3.13%. The relative deviation of the surface radiuses between the experiment and the target profile is 0.52%, and mechanical properties meet target design requirements. To sum up, the established finite element model can accurately predict the shape and property evolution of the stress relaxation aging process of the cover, and can be used to guide the stress relaxation aging forming of the 2219 aluminum alloy tank cover.

      The paper aims at the problems of inaccurate positioning of part, mould deformation at high temperature condition, and deformation of component surface in the process of composite materials. Laser tracker and laser radar equipment are used to detect and analyze the physical and technological process of composite materials. The solutions that digital detection technology is used for auxiliary locating and guiding assembly, applied for surface inspection of product and mold, and conducting manufacturing are put forward, and effectively improve the quality of composite materials.

      Airborne laser is influenced by atmospheric optical effect obviously. Thus it is useful to study the beam shaping system represented by adaptive optics, which would effectively improve the beam quality of laser at the target position. It is a feasible solution to use an adaptive mirror in the optical path by energy feedback, to calibrate the laser beam quality emitted by the airborne laser unit. An optimization algorithm, represented by the Stochastic Parallel Gradient Descent method, SPGD method, was applied in the adaptive mirror. It realized the maximum energy of return light, so as to improve the beam quality on the target. By optimizing SPGD algorithm and simulating a global convergence, a practical method of rapid convergence was proposed for beam quality correction of continuous laser and reproducible pulse laser. The simulation of the above algorithm is helpful to improve the performance of laser under an airborne condition, which would have a certain practical value.

      According to the requirements of aero-engine weight reduction design, based on the characteristics of light and high strength of TiB2 particle-reinforced aluminum matrix composites, the paper focuses on the stator vanes structure of a certain aero-engine low pressure compressor (LPC), finishes the job on design and machining of the specimen of particle-reinforced metal matrix composites, and studies on high cycle fatigue (HCF) test process. The results indicate that: (1) the design and manufacturing processes of specimens can achieve the goal of the HCF test; (2) the HCF strength of the specimens made from particle-reinforced metal-matrix composites is 246.30MPa, which can achieve the goals of the test; (3) the particle-reinforced metal-matrix composites used in this kind of stator vane specimen can meet the aero-engine design requirement for LPC stator vanes.

      The influence of test parameters on the test results of the commonly used damping characteristics test method was studied. The analysis show that the test data dispersion of the free vibration method is small and the test data dispersion of the half-power bandwidth method is large and greatly affected by the selection of test parameters. The damping characteristics of hollow and solid structures were compared and analyzed based on the optimized test parameters. It is found that the damping characteristics of the two types of structures are similar when the amplitude is small, and the modal damping under the first mode is about 2×10–3. Under the condition of high amplitude, damping radio of the solid structure increases slightly. When the amplitude is 10mm, the damping is 3.577×10–3, which is as many as 1.20 times that of the amplitude being 3.0 mm. It indicates that the internal structural features of the structure can provide additional damping under large deformation conditions. The rational use of this feature is of great significance to improve the structural performance.

      In the aircraft skin hammer riveting, the deformation of the rivet needs several tens of impacts to realize, and the problem of the initial speed loading cycle of the hammer rivet piston brings difficulties to the analysis process. This paper proposes a software method of automatic analysis of continuous hammer and rivet process by secondary development using the extremely extensibility of Python in ABAQUS. Through the adjustment of input parameters such as initial speed, analysis time and impact times, the hammer and rivet simulation analysis is completed automatically to make the rivet meet the deformation requirements. Compared with the manual single iteration method, the proposed software method and the corresponding simulation program greatly improve the efficiency of hammer riveting simulation analysis under the condition of guaranteeing the heading forming, and bring about the further research on the process parameters optimization and riveting quality evaluation guidance and convenience. Compared with the hammer riveting technology test, the simulation results verify the correctness.