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When processing aluminum alloy structural parts, customers found that due to the influence of material properties and processing stress, the workpiece was prone to deformation, resulting in product size deviation and high scrap rate. Our engineering team simulated the processing process through finite element analysis software to find out the cause of deformation. In terms of technology, we adopted step-by-step processing, reasonable arrangement of processing sequence, and increased aging treatment to effectively control processing deformation. Finally, the scrap rate was reduced from the original 30% to less than 5%, which improved the customer's product qualification rate and production efficiency.