Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts

Wei, Yu; Wang, X. W.

doi:10.1007/s00170-006-0470-1

Cited by 58 publications

(13 citation statements)

References 3 publications

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“…Wei and Wang [17] established a finite element model of original residual stress to analyze the corresponding deflection by machining aerospace thin-walled parts, especially in machining large aerospace parts, and simulation results were validated approximately consistent with experimental results. Yaghi et al [18] discussed the residual stress in thin-and thick-walled stainless steel pipe-welded components and presented a brief review of weld simulation, and analyzed more FE models with an inside radius to wall thickness ratio to investigate the effect of pipe diameter on residual stress.…”

Section: Introductionmentioning

confidence: 79%

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

Zhang

2016

Metals

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Abstract:The deformation of aeronautical monolithic components due to CNC machining is a bottle-neck issue in the aviation industry. The residual stress releases and redistributes in the process of material removal, and the distortion of the monolithic component is generated. The traditional one-side machining method will produce oversize deformation. Based on the three-stage CNC machining method, the quasi-symmetric machining method is developed in this study to reduce deformation by symmetry material removal using the M-symmetry distribution law of residual stress. The mechanism of milling deformation due to residual stress is investigated. A deformation experiment was conducted using traditional one-side machining method and quasi-symmetric machining method to compare with finite element method (FEM). The deformation parameters are validated by comparative results. Most of the errors are within 10%. The reason for these errors is determined to improve the reliability of the method. Moreover, the maximum deformation value of using quasi-symmetric machining method is within 20% of that of using the traditional one-side machining method. This result shows the quasi-symmetric machining method is effective in reducing deformation caused by residual stress. Thus, this research introduces an effective method for reducing the deformation of monolithic thin-walled components in the CNC milling process.

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Section: Introductionmentioning

confidence: 79%

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

Zhang

2016

Metals

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“…Measurement parameters are listed in Table 3. Besides, in order to measure the residual stress in-depth, the electro-chemically polishing method, one of peeling methods [28], was used. Compared to chemical corrosion [29], the electro-chemically polishing method is more efficient.…”

Section: Methodsmentioning

confidence: 99%

Semi-Empirical Prediction of Residual Stress Profiles in Machining IN718 Alloy Using Bimodal Gaussian Curve

et al. 2019

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Residual stresses are often imposed on the end-product due to mechanical and thermal loading during the machining process, influencing the distortion and fatigue life. This paper proposed an original semi-empirical method to predict the residual stress distribution along the depth direction. In the statistical model of the method, the bimodal Gaussian function was innovatively used to fit Inconel 718 alloy residual stress profiles obtained from the finite element model, achieving a great fit precision from 89.0% to 99.6%. The coefficients of the bimodal Gaussian function were regressed with cutting parameters by the random forest algorithm. The regression precision was controlled between 80% and 85% to prevent overfitting. Experiments, compromising cylindrical turning and residual stress measurements, were conducted to modify the finite element results. The finite element results were convincing after the experiment modification, ensuring the rationality of the statistical model. It turns out that predicted residual stresses are consistent with simulations and predicted data points are within the range of error bars. The max error of predicted surface residual stress (SRS) is 113.156 MPa, while the min error is 23.047 MPa. As for the maximum compressive residual stress (MCRS), the max error is 93.025 MPa, and the min error is 22.233 MPa. Considering the large residual stress value of Inconel 718, the predicted error is acceptable. According to the semi-empirical model, the influence of cutting parameters on the residual stress distribution was investigated. It shows that the cutting speed influences circumferential and axial MCRS, circumferential and axial depth of settling significantly, and thus has the most considerable influence on the residual stress distribution. Meanwhile, the depth of cut has the least impact because it only affects axial MCRS and axial depth of settling significantly.

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“…The clamping force and residual stress can bring the deformation of aero-engine blade. 15–17 So the compensation methods are popular in the machining of blade with two ends fixed.…”

Section: Cantilever Grinding Of Aero-engine Bladementioning

confidence: 99%

Study on the cantilever grinding process of aero-engine blade

Meng

Chen

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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An aero-engine blade is the typical thin-walled workpiece with low rigidity. The machining accuracy of the aero-engine blade with sculptured surfaces has been a research focus in the aviation industry. This article presents a new cantilever grinding process for the high precision machining of aero-engine blade. Only one end of a blade is fixed and the other end is free in order to eliminate the deformation of blade caused by over-positioning. Moreover, the vibration of aero-engine blade can be reduced so that the surface quality of blade can be improved in the grinding. The grinding parameters are optimized for the low deflections of blade. The types of tool path are also discussed in this article. Finally, the computer numerical control machining examples are implemented. The measurement results show that the profile errors of suction/pressure surface machined by the proposed process do not exceed 0.02 mm. And the machining accuracy of leading/trailing edge with a radius of about 0.05 mm is acceptable.

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Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts

Cited by 58 publications

References 3 publications

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

Semi-Empirical Prediction of Residual Stress Profiles in Machining IN718 Alloy Using Bimodal Gaussian Curve

Study on the cantilever grinding process of aero-engine blade

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