Effect of machining-induced residual stress on the distortion of thin-walled parts

Masoudi, Soroush; Amini, Saeid; saeidi, E. Pour; Eslami-Chalander, Hamdollah

doi:10.1007/s00170-014-6281-x

Cited by 132 publications

(50 citation statements)

References 18 publications

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“…The material of workpiece was Inconel 718 with the chemical composition according to Table 1. The workpiece before machining was relief annealed and aged to a nominal buck hardness about 45HRC with the density 8.24 g/cm 3 . The work material was prepared in 300*200 *20 mm blocks.…”

Section: Methodsmentioning

confidence: 99%

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Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718

Wang

Zhang

et al. 2017

Mat. Res.

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Inconel 718 is widely used in the aviation, space, automotive and biomedical industries because of its outstanding properties. Near-surface residual stresses that are induced by ball end milling in Inconel 718 can be crucial for the performance and service time of the machined parts. In this paper, the influences of cutting conditions, including the use of cutting parameters, cutting fluid and spindle angles, on the residual stresses in the ball end milling process of Inconel 718 alloy were investigated experimentally. X-ray diffraction measurements reveal that residual stress distributions are highly influenced by cutting parameters, especially the depth of cut and cutting speed. The milling operation with cooling induces more compressive stresses trend and the magnitude of the residual stresses increases in the tensile direction with the increase of spindle angles. These cutting induced effects were further discussed with respect to thermal-mechanical coupling theory and some observations made by optical microscopy. From this investigation, it is suggested that the machining process parameters are not the smaller the better for the control of residual stresses in the ball end milling process of Inconel 718.

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Section: Methodsmentioning

confidence: 99%

“…The reliability of a precision component depends to a large extent on the distribution of residual stresses induced by machining 3 . The residual stress distribution on a component may cause distortion after releasing fixtures.…”

Section: Introductionmentioning

confidence: 99%

Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718

Wang

Zhang

et al. 2017

Mat. Res.

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“…It was observed that, σ x = -168.89 MN/m² is the highest residual stress in sample 1, which is observed from point 3, σ x = -173.41 MN/m² is the highest residual stress in sample 2, and it is obtained from point 3, and σ x = -139.81 MN/ m² is the highest residual stress in sample 3, and it is also determined from point 3 of the block. Therefore, relieving these stresses is very important to improve the reliability of the 2219 aluminium block and also to avoid the failure of manufactured components [23] to [25].…”

Section: Residual Stresses After Quenchingmentioning

confidence: 99%

Determination of the Effect of Cold Working Compression on Residual Stress Reduction in Quenched Aluminium Alloy 2219 Block

Ahmad¹,

Wu²,

Gong³

et al. 2019

SV-JME

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Residual stresses are induced in components during mechanical, thermal, machining, and plating operations. If not carefully considered in the design process, residual stress can be a significant factor in the failure of components, particularly when subjected to alternating service loads or corrosive environments. The induced residual stresses in three quenched aluminium alloy 2219 blocks were experimentally investigated, and cold working compression was performed at room temperature to relieve the stresses. High residual stresses were observed in the blocks after quenching. Therefore, their reduction became necessary to improve the tolerance of machined parts and avoid their failure. The samples were cold-worked at various compression ratios (CR). The residual stresses were significantly relieved, and it was discovered that 2 % CR offers a considerable effective reduction in the residual stress. Relieving these residual stresses will improve the reliability of the samples and the components to be manufactured.

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“…Coto et al [16]'s specific research on the effects of feeding and cutting speeds on the tensile residual stress demonstrated that the tensile residual stress increased with the accelerating feeding, while decreased with the accelerating cutting within a certain range. Masoudi et al [17] found that the cutting force and temperature had direct effects on the curved surface residual stress and deformation of thin-walled parts. Singh and Agrawal [18] conducted an experimental study on the residual stress of the surface in deformation processing, and found that the residual stress of the surface significantly changed with the change of machining and forming parameters.…”

Section: Introductionmentioning

confidence: 99%

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

Kong

Zhou

Xu³

et al. 2019

EPJ Web Conf.

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With the increasing application of curved thin-walled parts, the evaluation and control of curved surface residual stress in milling are becoming increasingly demanding. However, effects of milling parameters on distribution of residual stress remains a major challenge in the present aerospace research areas. In this paper, , impacts of milling parameters on curved surface residual stress have been investigated in a series of residual stress experiments and simulations. It is found that the residual stress can be lowered by increasing milling speed and tool radius within a reasonable range. The superposition of curved surface residual stress under two machining conditions have been analyzed using the milling simulation model. It has been found that the curved surface residual stress induced by the subsequent cutting will be superimposed on the curved surface residual stress induced by the previous cutting and that the superposition rates of residual stress induced by up milling are larger than down milling.

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Effect of machining-induced residual stress on the distortion of thin-walled parts

Cited by 132 publications

References 18 publications

Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718

Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718

Determination of the Effect of Cold Working Compression on Residual Stress Reduction in Quenched Aluminium Alloy 2219 Block

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

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