Authors: A.A. Pashkov, O.V. Samoylenko, A.A. Duk, S.U. Faleev, D.A. Aleynikov

Title of the article: Definition of input parameters for modeling the technological process of flap abrasive wheel grinding

Year: 2025, Issue: 2, Pages: 57-67

Branch of knowledge: 2.5.6. Engineering technology

Index UDK: 621.98.042

DOI: 10.26730/1999-4125-2025-2-57-67

Abstract: The ability of increasing the operational characteristics of products and components used in machine engineering is a significant task, the successful completion of which allows for a reduction in labor intensity, material savings, and economic benefits. The capabilities of modern shaping equipment enable achieving shapes and dimensions of manufactured parts that closely resemble those of digital twins. Currently, the technology of abrasive processing with flap discs is widely and effectively used for subsequent treatment after shot peening forming of large, low-rigidity components like aircraft wing panels and skins. Here, abrasive flap discs on specialized machines are employed to remove imprints or reduce the depth of plastic deformations after shot peening. The quality of the surface layer during flap disc cleaning, including roughness and residual stresses, not only determines the shape of the part after shot peening but also its fatigue strength. These factors depend on numerous variables, such as processing modes, properties of the material being machined, and tool parameters. Predicting and determining the values of these indicators is a labor-intensive and economically costly process. Therefore, there is a need for modeling these processes using mathematical models. However, until now, most researchers in this field model the flap disc cleaning process using the finite element method with a simple abrasive model and numerous assumptions about the interaction of abrasives with the surface of the part, which does not yield reliable results. The aim of this work is to determine the input parameters for modeling the technological process of flap disc cleaning by conducting laboratory research on abrasives and their distribution in flap discs used in the production of panels and skins, as well as modeling the process of single abrasive penetration using finite element analysis software. Based on the results of laboratory studies, the shape of the abrasive and its distribution on the surfaces of the flaps used in real production conditions were determined, allowing for the transfer of the obtained relief into engineering analysis software. Based on the results of laboratory research, finite element modeling of the single abrasive penetration process into the material was performed to determine residual stresses in the surface layer of the part.

Key words: panel wing skin forming grinding internal force factors modeling surface plastic deformation

Receiving date: 02.09.2024

Approval date: 22.04.2025

Publication date: 11.06.2025

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