Semi-Analytical Solution Model for Bending Deformation of T-Shaped Aviation Aluminium Alloy Components under Residual Stress

Structures composed of aviation aluminium alloys, characterized by their limited rigidity and thin-walled configurations, frequently exhibit deformation after processing. This paper presents an investigation into T-shaped components fabricated from pre-stretched 7075-T7451 aviation aluminium alloy sheets, examining the effects of residual stress and the geometrical parameters of T-shaped components on their deformational behavior. A semi-analytical model, developed to elucidate the bending deformation of T-shaped components subjected to residual stress, was validated through finite element analysis and empirical cutting experiments. The experimental results revealed that the bending deformation deflection of the T-shaped specimen was 0.920 mm, deviating by a mere 0.011 mm from the prediction provided by the semi-analytical model, resulting in an inconsequential error margin of 1.2%. This concordance underscores the precision and accuracy of the semi-analytical model specifically designed for T-shaped components. Moreover, the model’s simplicity and ease of application make it an effective tool for predicting the bending deformation of thin-walled T-shaped components under a range of residual stresses and dimensional variations, thereby demonstrating its significant utility in engineering applications.