Monolithic part and process for making the same

1. A process for producing a monolithic part comprising the steps of:

providing a piece of stock;

rough machining the piece of stock, leaving sufficient material to provide for finish machining;

forming the piece of stock, initially over forming the piece of stock beyond a final desired contour followed by forming the piece of stock to the final desired contour;

clamping the formed piece of stock for semi-finish machining, and semi-finish machining the piece of stock;

releasing the piece of stock, thereby allowing the piece of stock to find a neutral position;

reclamping the piece of stock; and

finish machining the piece of stock.

2. The process according to claim 1 , further comprising releasing, deburring and applying finish treatments to the piece of stock.

3. The process according to claim 2 , wherein said steps are performed in the order recited.

4. The process according to claim 1 , further comprising machining gauge points and attachment features into the piece of stock.

5. The process according to claim 1 , wherein the piece of stock is over formed beyond its intended final shape, then formed back to its final shape.

6. A process for producing a monolithic part comprising the steps of:

providing a piece of stock,

rough machining the piece of stock;

forming the piece of stock;

clamping the formed piece of stock for semi-finish machining, and semi-finish machining the piece of stock;

releasing and reclamping the piece of stock; and

finish machining the piece of stock;

wherein the monolithic part comprises a skin portion and a support frame portion.

7. The process according to claim 6 , wherein the skin portion and support frame portion are integral.

8. A process for forming a monolithic part comprising:

providing a work piece;

rough machining the work piece leaving sufficient material for finish machining;

over-forming the work piece through cold forming, wherein the work piece is overformed;

forming the over-formed work piece to a desired shape to reduce residual stress occurring in the over-formed shape; and

finish machining the work piece using high velocity machining.

9. The process of claim 8 , further comprising:

semi-finish machining the work piece prior to finish machining the work piece;

releasing the work piece after semi-finish machining; and

reclamping the work piece prior to finish machining.

10. A process for forming a monolithic part comprising:

providing a work piece;

rough machining the work piece leaving sufficient material for finish machining;

over-forming the work piece through cold forming, wherein the work piece is overformed;

forming the over-formed work piece to a desired shape to reduce residual stress occurring in the over-formed shape, wherein forming the work piece includes utilizing a hydraulic brake; and

finish machining the work piece using high velocity machining.

11. A process for forming a monolithic part comprising:

providing a work piece;

rough machining the work piece leaving sufficient material for finish machining;

over-forming the work piece through cold forming, wherein the work piece is overformed;

forming the over-formed work piece to a desired shape to reduce residual stress occurring in the over-formed shape; and

finish machining the work piece using high velocity machining;

wherein the work piece includes an inner surface having integrated ribs and integrated stringers, wherein the ribs and the stringers have residual stress levels within predefined parameters.