In this paper, the effects of material removal strategies and initial stress states on the machining deformation of aluminum alloy plates were investigated through a combination of finite element simulation and experiments. We developed different machining strategies described by Tm+Bn, which removal m mm materials form top and n mm materials from the bottom of the plate. The results demonstrate that the maximum deformation of structural components with the T10+B0 machining strategy could reach 1.94 mm, whereas with the T3+B7 machining strategy was only 0.065 mm, decreasing by more than 95%. The asymmetric initial stress state had a significant impact on the machining deformation of the thick plate. The machined deformation of thick plates increased with the increase in the initial stress state. The concavity of the thick plates changed with the T3+B7 machining strategy due to the asymmetry of the stress level. The deformation of frame parts was smaller when the frame opening was facing the high-stress level surface during machining than when it was facing the low-stress level. Moreover, the modeling results for the stress state and machining deformation were accurate and in good accordance with the experimental findings.

This study investigates the machining deformation of thick aluminum alloy plates, specifically in aerospace frame components, focusing on the influence of asymmetric residual stress states and machining strategies. Aluminum alloys are commonly used for large structural components due to their strength, formability, and corrosion resistance. However, machining these components often leads to deformation caused by residual stress release, cutting forces, and thermal effects. Using finite element simulations and experimental validation, the study analyzes how asymmetric residual stresses, induced by spray quenching, affect deformation patterns during machining. It is found that lower initial stress asymmetry results in less deformation, while machining sequences that optimize stress release significantly reduce the final distortion. Among the strategies tested, the diagonal milling sequence yielded the smallest deformation, achieving a reduction of up to 4%. The study concludes that both the initial residual stress state and the machining strategy are critical in controlling deformation, offering insights for improving machining processes in aerospace manufacturing to enhance precision and reliability.