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<p>Large-scale thin-walled (LSTW) spacecraft cabin components are widely used in aerospace. High-precision manufacturing of mounting surfaces for local brackets on LSTW spacecraft cabins is essential to ensure the reliability of the spacecraft. Robotic in-situ integrated machining provides a feasible solution for high-precision manufacturing. However, the spacecraft cabin, due to its large size and low rigidity, is prone to overall elastic deformation during machining. Additionally, discrepancies between the actual and designed machining allowances, due to the cabin’s overall manufacturing tolerances and bracket installation errors, can cause further issues. Machining based solely on the theoretical model and uniform design allowances may lead to machining instability, and the precision of the brackets after machining may fail to meet design standards. Therefore, in the robotic integrated machining process of these cabins, accurate tool path planning for local brackets is critical for controlling machining precision. This paper proposes a tool path mapping and adaptive planning method that considers non-uniform allowances, overall elastic deformation, and manufacturing errors in spacecraft cabins. The method addresses surface offsets caused by elastic deformation rebound and inaccuracies from non-uniform allowances. First, by calculating offsets due to the cabin’s overall elastic deformation and mapping the nominal tool path poses, the method ensures accurately incorporate pose changes into path planning. Then, based on actual blank surface measurement data, the adaptive tool path planning method generates paths that are precisely tailored to the brackets. Finally, machining and measurement experiments on a thin-walled cabin workpiece showed that this approach reduced dimensional error in the brackets by over 90% (maximum dimensional error reduced from 1.67&#xa0;mm to 0.13&#xa0;mm) and angular error by more than 70% (maximum angular error reduced from 8.98’ to 2.64’), achieving high-precision machining of local brackets in LSTW cabins.</p> Graphical Abstract <p></p>

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Adaptive Tool Path Mapping and Planning Method for Non-Uniform Machining Allowances of Large-Scale Thin-Walled Cabin Brackets

  • 期刊论文

  • 发表日期：

    2025年10月14日

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  • Jian-wei Ma,
  • Hui-teng Yan,
  • Yong Wang,
  • Yao-wu Song,
  • Lin-yu Li,
  • Yun-peng Wang,
  • Zhen-yuan Jia

摘要

Large-scale thin-walled (LSTW) spacecraft cabin components are widely used in aerospace. High-precision manufacturing of mounting surfaces for local brackets on LSTW spacecraft cabins is essential to ensure the reliability of the spacecraft. Robotic in-situ integrated machining provides a feasible solution for high-precision manufacturing. However, the spacecraft cabin, due to its large size and low rigidity, is prone to overall elastic deformation during machining. Additionally, discrepancies between the actual and designed machining allowances, due to the cabin’s overall manufacturing tolerances and bracket installation errors, can cause further issues. Machining based solely on the theoretical model and uniform design allowances may lead to machining instability, and the precision of the brackets after machining may fail to meet design standards. Therefore, in the robotic integrated machining process of these cabins, accurate tool path planning for local brackets is critical for controlling machining precision. This paper proposes a tool path mapping and adaptive planning method that considers non-uniform allowances, overall elastic deformation, and manufacturing errors in spacecraft cabins. The method addresses surface offsets caused by elastic deformation rebound and inaccuracies from non-uniform allowances. First, by calculating offsets due to the cabin’s overall elastic deformation and mapping the nominal tool path poses, the method ensures accurately incorporate pose changes into path planning. Then, based on actual blank surface measurement data, the adaptive tool path planning method generates paths that are precisely tailored to the brackets. Finally, machining and measurement experiments on a thin-walled cabin workpiece showed that this approach reduced dimensional error in the brackets by over 90% (maximum dimensional error reduced from 1.67 mm to 0.13 mm) and angular error by more than 70% (maximum angular error reduced from 8.98’ to 2.64’), achieving high-precision machining of local brackets in LSTW cabins.

Graphical Abstract