A 3D analytical model for residual stress in flank milling process

Wang, S.Q.; Li, J.G.; He, Chao; Xie, Zhijie

doi:10.1007/s00170-019-04046-w

Cited by 10 publications

(2 citation statements)

References 34 publications

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“…More recent work by Shan et al [11] studied the prediction of residual stress in cutting of Ti-6Al4V under orthogonal conditions. Recent (2019) work by Wang et al [12] and Zhou and Yang [13] deals with 3D analytical modeling of residual stresses in flank milling and milling complex surfaces, respectively. Other researchers, such as Li et al [14] continue to refine semi-analytical modeling approaches to predict machining deformation in thinwalled parts, which is a major concern for the aerospace industry.…”

Section: Introductionmentioning

confidence: 99%

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Schoop

2021

Lubricants

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Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades).

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Section: Introductionmentioning

confidence: 99%

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Schoop

2021

Lubricants

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“…Fergani et al [2,3] established an analytical model for residual stress regeneration in milling and predicted the residual stress distribution in multi-pass milling and proposed an analytical model to predict the deformation of thin-walled parts caused by residual stress. Wang [4] established an analytical model of residual stress for flank milling. The model applied the radial return method to update the plastic stress components during the plastic loading process.…”

Section: Introductionmentioning

confidence: 99%

Analytical Prediction of Residual Stress in the Machined Surface during Milling

Yue

Hao

et al. 2020

Metals

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An analytical prediction model for residual stress during milling is established, which considers the thermal-mechanical coupling effect. Considering the effects of thermal-mechanical coupling, the residual stress distribution in the workpiece is determined by the stress loading history according to McDowell′s hybrid algorithm. Based on the analysis of the geometric relationship of orthogonal cutting, the prediction model for milling force and residual stress in the machined surface is established. The research results can provide theoretical basis for stress control during milling.

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