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Modeling and Optimal Design of Machining-Induced Residual Stresses in Aluminium Alloys Using a Fast Hierarchical Multiobjective Optimization Algorithm

This paper is the result of an international multi-disciplinary European programme (“COMPACT” FP6-Aerospace, €3.7M). We investigated manufacturing induced distortion of aerospace components. The new model-based approach developed by Panoutsos predicts the residual-stress profile of aluminium components. The main research results of this work informed Airbus-UK (Dr. Sim, WeiMing.Sim@airbus.com), along with the rest of the work packages of the COMPACT project, on how to fine-tune the design of critical components, towards preventing ‘part distortion’. Avoiding part distortion reduces the manufacturing cost and eliminates material waste - as opposed to traditional practices involving component over-design and post-manufacturing machining of distorted material.