To improve the machining quality of mirror milling of thin-walled parts, this paper proposes a collaborative motion control strategy for mirror milling of dual hybrid robots. Firstly, based on the characteristics of robot motion control, an open CNC system with a dual CPU master-slave control architecture is developed to achieve human–computer interaction and motion control. Then, in order to achieve dual robots collaborative motion and improve the machining quality of thin-walled parts, four key technologies are integrated into the CNC system, namely mirror path generation of dual robots, synchronous speed planning, collaborative kinematics, and real-time compensation of motion errors. Finally, based on the independently developed integrated mirror milling CNC system, flat thin-walled part slot milling experiments with single and multi-point support, dual robots collaborative and non collaborative machining, multipoint support surface milling experiments, high curvature path high-speed collaborative motion experiments, and curved thin-walled part slot milling experiments are carried out. The experimental results show that the proposed collaborative motion control strategy can ensure high synchronization position accuracy of the dual robots. In addition, the multi-point support method can improve the vibration stability of workpiece milling while ensuring the wall thickness of thin-walled parts.

To solve the problem of datum failure caused by deformation of workpieces during mirror milling, a kinematic model of wall thicknesses for mirror milling based on screw theory was established. Considering comprehensively of parts machining requirements and mirror milling constraints, a“ support–milling” trajectory generation method was proposed. Meanwhile, a supporting trajectory adjustment model for deformation compensation was developed. Then automatic trimming of the“ support–milling” trajectory for mirror milling was realized. The results of the verification experiments on the grid mirror milling of thin-walled parts show that the “support–milling” trajectory generation and automatic adjustment method for mirror milling can meet the requirements of the wall thickness for mirror milling.

The precision and efficiency of the machining of aerospace thin-walled parts directly affect the performance and reliability of aircraft. This paper provides a systematic review of aerospace thin-walled part cutting technology, including fixture technology, deformation prediction and control methods, chatter prediction and control technology, as well as the application of digital twin technology. The fixture technology section presents a detailed study on the operational mode, structural features, functionality and applications of various fixtures. The deformation prediction and control section analyzes the causes of thin-walled part deformation and introduces related control technologies and methods. The chatter prediction and control section discusses the stability analysis technique of cutting processes and the technology of chatter control, including online monitoring and recognition, active and passive control technologies and methods. The application section of digital twin technology introduces the actual application of this technology in thinwalled part machining. By providing a comprehensive and in-depth overview of the aerospace thin-walled component manufacturing technology, this study offers valuable references and guidance for scholars in their research endeavors.

In the aerospace field, thin-walled structural parts are connected and assembled with extremely high precision, the holes for the connections therefore have high tolerance requirements. Due to its low stiffness, there is a great deal of deformation and vibration in the drilling process, which seriously affects the drilling precision and quality. Aiming at the problems of large clamping span, insufficiency and difficulty in effectively supporting the aircraft wing box and other components in the traditional clamping method, this paper proposes to improve the local stiffness during the drilling of thinwalled structural parts through the positive adsorption auxiliary support, which in turn improves the drilling quality of the thin-walled structural parts, and investigates the effect of positive adsorption auxiliary support on the drilling of the thinwalled structural parts through the combination of simulation and experiments. The results show that under the simulation and experimental conditions in this paper, the positive adsorption auxiliary support can improve the stiffness of the drilling position by more than 40 times, reduce the roughness of the hole wall by more than 67%, reduce the roundness tolerance by more than 60%, reduce the deviation of the hole entrance and exit diameters by more than 90%, and reduce the aperture deviation by more than 50%, so that the positive adsorption auxiliary support can significantly improve the precision and quality of the thin-walled structural parts.

To tackle the efficiency and precision control issues in the complex five-axis machining of aeronautical turbines, this study thoroughly investigates the effects of machining parameters on surface roughness and processing time using direct-drive machine tools. The superiority of direct-drive machine tools over conventional ones in terms of precision and speed is initially established through comparative machining. Research focusing on the origin coordinates then reveals a significant enhancement in machining efficiency, particularly when the origin is near the centers of the A and C axes. Employing an orthogonal experimental approach, the study examines spindle speed, feed per tooth, and cutting width, identifying the feed per tooth as the primary factor influencing surface roughness, followed by cutting width, with spindle speed having a lesser impact. The study achieves optimal results under parameters that maintain a roughness below 1.6 μm: 20000 r/min spindle speed, 0.03 mm feed per tooth, and 0.6 mm cutting width. These optimized parameters not only improve machining efficiency by 43.3%, but also ensure quality, providing vital technical insights for the precision machining of aeronautical turbines and offering both practical and theoretical guidance for the efficient machining of complex parts on direct-drive machine tools.

Thin-walled blades are characterized by complex structures, low rigidity, and challenging material processing. During the manufacturing process, they are subjected to deformation caused by various sources such as tool wear and machine tool accuracy evolution, causing poor machining precision and long production time. To address this issue, a modeling and compensation method of machining errors for thin-walled blades was proposed, in which a machine learning algorithm was adopted to establish the machining error model. Meanwhile, a real-time error compensation system based on the external machine zero-point shift function of the NC system was developed to offset the machining error. Finally, a milling experiment for thin-walled blades was conducted to verify the proposed method. The experiment results revealed that the machining errors, including both elastic deformation and plastic deformation, were significantly reduced after the machine measurement and compensation process, effectively improving the machining accuracy.

Thin-walled structures are widely used in the aerospace field because of their light weight and high specific strength. However, due to its complex structure, weak rigidity and high material removal rate, the finished parts processed by milling are prone to machining errors, which seriously affects their performance. Therefore, controlling the machining error of thin-walled structures has important practical significance. By analyzing the machining characteristics of thin-walled structure, the source of machining error of thin-walled structure is summarized. According to the sources of machining errors, different types of machining errors of thin-walled structures are introduced, including clamping positioning, cutting load, cutting vibration, machine tool errors, residual stresses, and multi-process machining. Then the prediction and control methods of machining errors of thin-walled structures are summarized from these six aspects. Finally, the current challenges and future development of control methods for milling errors in thin-walled structures are expounded.

With the rise of “Industry 4.0” and “Made in China 2025”, the level of intelligent manufacturing and automation in the manufacturing industry has been  ontinuously improved. As an important part of the production process, cutting tools have become more precise and intelligent. Intelligent cutting tool is an important link and necessary guarantee to realize intelligent manufacturing and automatic production. This paper discusses in detail the latest research progress of intelligent tools, including intelligent tool design, key technologies of intelligent tools, digital twin technology and intelligent tool systems. The research results of scholars on integrated optimization and design of intelligent tool, intelligent tool monitoring and control technology, and intelligent tool system based on tool control and recommendation are summarized. The application of digital twin technology in the field of intelligent tool is briefly described, and the current shortcomings and future development direction of intelligent tool are pointed out.

Impact testing techniques based on electromagnetic loading were proposed to solve the problems of loading speed, loading force, safety problems and single mode of the existing impact testing technology. The accurate control of pulse width, amplitude and loading speed of pulse electromagnetic force can be realized by adjusting the power control parameters (mainly is capacitance and charging voltage) of electromagnetic driving impulse testing technology. The fast conversion of tension-compression test can be realized by changing the direction of electromagnetic loading head. In addition, as more and more attention has been paid to the testing of dynamic mechanical properties of materials under compound impact loads, multi-axis testing based on electromagnetic drive can accurately control the simultaneous discharge of multiple groups of capacitors through the control program，so as to ensure the synchronization of the isotropic impact load acting on the specimen material. Therefore, the testing technology based on electromagnetic loading has the advantages of good controllability, high repeatability, high synchronization of compound loading, high testing accuracy and experimental efficiency. The problems of traditional testing methods, such as small loading speed range, limited strain rate range and difficult impact testing with large loading force, are solved, and the safe, stable, reliable and more accurate control and measurement of impact testing experiment are realized.

In order to predict the static friction of grinding surface more accurately, based on fractal geometry theory, Hertz contact theory and tangential contact load theory, the actual contact area, total normal contact load, and total tangential contact load are deduced and the fractal model of static friction coefficient is established accounting for asperity interaction and the domain extension factor. The effects of total normal contact load, fractal dimension, and height scaling parameter as well as material parameters on the static friction coefficient are investigated. Calculation results show that the static friction coefficient increases with the increase of normal contact load. The static friction coefficient decreases as the height scaling parameters or material parameters increase. The static friction coefficient depends sensitively on the fractal dimension and exhibits nonmonotonic characteristics. The static friction coefficient increases with the increasing of fractal dimension as the fractal dimension is less than 2.65; the static friction coefficient increases with the decreasing of fractal dimension as the fractal dimension is more than 2.65. Finally, the effectiveness of the static friction coefficient is compared with the existing model as well as experimental results.

In the large-space measurement of various aviation components, in view of the high workload of manual measurement, unstable detection accuracy and low detection efficiency, a contact measurement robot station planning method based on omnidirectional mobile compound robot is proposed. Firstly, the robot D–H parameters are established and the joint angle is solved, and the measurement accessibility constraint model is constructed. Analyze the impact of the tool end on the robot workspace and the laser accessibility between the T–Mac and the laser tracker; then carry out the robot station planning algorithm flow for the axial and radial directions of the engine according to the maximum working limit and joint angle limit constraints developed to ensure that the measurement feature points are within the working limit of the robot; finally, based on the AnyCAD geometry engine, the CAD model measurement feature point extraction, station planning, and measurement simulation are carried out in the 3D virtual environment. The planning results are verified and evaluated through the example simulation test: the station planning algorithm can ensure the robot accessibility and laser accessibility of all measurement points.

Carbon fiber reinforced polyether ether ketone (CF/PEEK) is a kind of high performance thermoplastic composite material, which has broad application prospects in aviation manufacturing industry. There are significant differences in thermal history between the different axial and radial positions of the hole circumference in the process of hole making and cooling process of this material, and the cooling process is closely related to the recrystallization process of thermoplastic resin. In order to further clarify the influence of drilling heat on the performance around the hole, the effect of drilling heat on properties of CF/PEEK resin was studied in this paper. Firstly, the PEEK sample was pretreated by simulating the thermal history around the hole, and then the material mechanical parameters were measured. Secondly, the fiber parameters were introduced, the material mechanical parameters of CF/PEEK were deduced and the crystallinity was determined. Finally, the relationship between the cooling rate and the material properties was established, and the effect of drilling heat on the mechanical properties of CF/PEEK was clarified. It is found that as the cooling rate decreases, the lower cooling rate has a beneficial effect on the resin properties, the crystallinity of the PEEK matrix will increase, and the tensile strength will increase. While the tensile strength and elastic modulus of the material are the lowest under rapid cooling, which are 65.32 MPa and 3.3 GPa, respectively.