A Study of the Response Surface Methodology and Finite Element Method to Model Aircraft Engine Body Deformations During Hole Drilling

The aviation industry is still looking for effective manufacturing methods. Currently, the challenge is still the machining of shapes in thin-walled materials. This work focuses on the analysis of the influence of these parameters on deformations during the drilling process of holes in the adapters of aircraft engine body accessories. The drilling process was carried out in the thin-walled superalloy Inconel 718, which is classified as a difficult-to-machine material. During the analyses, experimental studies based on the Response Surface Method (RSM) and finite element method (FEM) calculations were carried out simultaneously. The aim of this work was to analyze the developed mathematical models describing nonlinear relationships between cutting parameters, cutting forces, and deformations of the aircraft engine body characterized by a complex, thin-walled geometric structure. By using the proposed solutions, it is possible to achieve integration between the techniques of conducting research, performing calculations using FEM, and designing the machining. The advantage of this comprehensive approach used in our work is the development of mathematical models that strongly fit the results of the research. The results of analyses and calculations presented in the article and the research methodology used can be applied to industrial conditions.