Coupling between inherent and machining-induced residual stresses in aluminum components

Mathews, Ritin; Sunny, Sumair; Malik, Arif; Halley, Jeremiah E.

doi:10.1016/j.ijmecsci.2021.106865

Cited by 22 publications

(3 citation statements)

References 51 publications

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“…At the same time, RS can be divided into two categories, namely Bulk or blank Initial Residual Stresses (BIRS) inherited from the upstream manufacturing processes and Machining Induced Residual Stresses (MIRS) as a result of the high-temperature gradients and plastic deformations produced by the cutter on the machined surface. According to the bibliography, BIRS and MIRS are the main distortion sources in the case of structural monolithic components for the aerospace market [6,7]. While BIRS causes distortion when stressed material is taken away, the initial equilibrium is broken and stress relaxation occurs; MIRS on the machined surface cause distortion as they introduce a bending moment into the part [8].…”

Section: Introductionmentioning

confidence: 99%

In-Process Machining Distortion Prediction Method Based on Bulk Residual Stresses Estimation from Reduced Layer Removal

Aurrekoetxea,

López de Lacalle,

Zelaieta

et al. 2024

JMMP

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Manufacturing structural monolithic components for the aerospace market often involves machining distortion, which entails high costs and material and energy waste in industry. Despite the development of distortion calculation and avoidance tools, this issue remains unsolved due to the difficulties in accurately and economically measuring the residual stresses of the machining blanks. In the last years, the on-machine layer removal method has shown its potential for industrial implementation, offering the possibility to obtain final components from blanks with measured residual stresses. However, this measuring method requires too long an implementation time to be used in-process as part of the manufacturing chains. In this sense, the objective of this paper is to provide a machining distortion prediction method based on bulk residual stress estimation and hybrid modelling. The bulk residual stresses estimation is performed using reduced layer removal measurements. Considering bulk residual stress data and machining-induced residual stress data, as well as geometry and material data, real-part distortion calculations can be performed. For this, a hybrid model based on the combination of an analytical formulation and finite element modelling is employed, which enables us to perform fast and accurate calculations. With the developments here presented, the machining distortion can be predicted, and its uncertainty range can be calculated, in a simple and fast way. The accuracy and practicality of these developments are evaluated by comparison with the experimental results, showing the capability of the proposed solution in providing distortion predictions with errors lower than 10% in comparison with the experimental results.

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Section: Introductionmentioning

confidence: 99%

In-Process Machining Distortion Prediction Method Based on Bulk Residual Stresses Estimation from Reduced Layer Removal

Aurrekoetxea,

López de Lacalle,

Zelaieta

et al. 2024

JMMP

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“…The reconstruction of initial residual stress field is one of the difficulties in stress coupling analysis of metal components. Ritin et al [9] carried out numerical simulation of initial residual stress field through the iterative stress reconstruction method in 7050 aluminum block, and realized coupling analysis of initial residual stress and machining induced residual stress on high-speed milling.…”

Section: Introductionmentioning

confidence: 99%

A novel genetic-based residual stress and deformation prediction method for the coupled machining process of connecting rod

Zhou¹,

Peng

Li³

et al. 2023

Preprint

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Residual stress is the main factor that causes the deformation of connecting rod during its coupled machining process. Thus, it is essential to predict the residual stress and deformation of the connecting rod before its machining. As the traditional independent analysis method is no longer suit to the coupled machining process, a novel genetic-based method is processed. Firstly, the genetic mechanism of residual stress field and deformation field was established to realize the effective correlation of multiple machining process simulation models. Secondly, a milling process was established based on the birth and death element method, which converts complex milling processes into dynamic loading of milling forces and the death of elements of the FEM model. It realizes the coupling of initial residual stress (IRS) and machining induced residual stress (MIRS). Then, a multi-process simulation model of heat treatment, cutting off, and milling of connecting rod is established, which can reveal the evolution law of residual stress field under multi-process coupling of connecting rod, the coupling mechanism between IRS and MIRS, and the deformation response law of big hole cylinder of connecting rod. The proposed method will have great significance to the deformation control of connecting rod.

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“…Madariaga et al [16] studied the effects of IRS and MIRS on distortion of monolithic aluminium parts and revealed that machining strategy optimization can minimize the part distortion. Mathews et al [17] investigated the coupling effects of RS on the nal-state RS and distortion of high-speed-machined and high-aspect-ratio aluminium components via 3D end-milling simulation and declared that the effects are nonlinear but the tool path is more signi cant. Weber et al [18] studied the repeatability of the machining-induced RS for different machining parameters and clamping strategies on distortion, and revealed that more and deeper machining-induced RS causes more distortion.…”

Section: Introductionmentioning

confidence: 99%

Study of distortion on milled thin-wall aluminum parts influenced by initial residual stress and toolpath strategy

Zheng

Voyle

Tang

et al. 2023

Int J Adv Manuf Technol

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Monolithic aluminium alloy parts are highly required in aeronautical industry, but they show signi cant geometrical distortion after the machining process. This work investigated the distortion attributed by the initial residual stress of raw material and the machining induced residual stress during the milling process, as well as explored the effects of the machining toolpath strategy. Single-/multi-pocket parts were milled from 7050-T7451 aluminium blocks with different initial residual stress, and an element deletion method was developed for numerical study to simulate different sequences of material removal.It was revealed that the toolpath parallel to the long side of block caused more distortion on the side surfaces of nal part. The value of distortion was positively correlated to the magnitude of initial residual stress of raw material. The simulation results indicated that the distortion attributed by machining induced residual stress accounted for about 15% of nal distortion. The nding promotes the design optimization of machining monolithic parts by minimizing distortion, thereby bene tting the application of large monolithic parts in industry.

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Coupling between inherent and machining-induced residual stresses in aluminum components

Cited by 22 publications

References 51 publications

In-Process Machining Distortion Prediction Method Based on Bulk Residual Stresses Estimation from Reduced Layer Removal

In-Process Machining Distortion Prediction Method Based on Bulk Residual Stresses Estimation from Reduced Layer Removal

A novel genetic-based residual stress and deformation prediction method for the coupled machining process of connecting rod

Study of distortion on milled thin-wall aluminum parts influenced by initial residual stress and toolpath strategy

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