Laser integration and novel nomenclature for multistage distortion measurement and geometry analysis in thin aluminum plates: Applications in aerospace manufacturing

Aluminum alloy thin parts perform a critical role in many industrial sectors, mainly in the aeronautic field. One of the main problems that may arise when manufacturing is the distortion of the part. This paper analyzes the effect that plate geometry and unclamping process may have on distortion. Besides, a laser sensor was used and validated for distortion measurement, which is integrable in the machining center and allows distortion measurement when machining and unclamping. Also, a novel nomenclature is suggested to label and classify distortion measurements on different stages of clamping, machining and unclamping, which is useful to precise when a distortion measurement is performed, which is essential for clear communication, data sharing and comparison. Regarding the final plate distortion, the analysis reveals that plate area is the most significant factor influencing distortion, whereas plate thickness exhibits less noticeable effect. In addition, unclamping has a negligible impact on the distortion of low area plates, whereas large area plates undergo notable changes in distortion shape and value during unclamping (up to 250 μm), so unclamping process should be considered prior to machining in order to control and prevent distortion.