Towards advanced prediction and control of machining distortion: a comprehensive review

Machining precision components involves challenging distortion issues that entail high costs and material and energy waste to the industry. In parallel, advanced control of production processes is a rapidly growing field because of its unique capabilities to solve multi-agent nonlinear problems and develop control actions based on knowledge and experience. Despite the several studies carried out on the subject, research keeps fragmenting distortion issues in different niches of components, and comprehensive reviews considering distortion as a cross-cutting technical hitch have never been reported. In this paper, a study compiling recent advances in machining distortion control from a holistic perspective is presented. For the first time, distortion understanding is unified, offering a new perspective, more practical and comprehensive, which includes intelligent systems. This novel way of attaining the research on distortion distinguishes three interconnected pillars: distortion source identification and quantification, distortion simulation model development, and control strategies drafting and application. The paper guides the reader through several distortion investigations of different kinds and provides classifications never addressed in the field with which a profound understanding of the issue can be achieved. Finally, future trends and key enabling technologies to drive the advanced control and minimization of machining distortions are outlined.