Finite element simulation and experimental investigation on the residual stress-related monolithic component deformation

Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal

“…Unlike the clamping effect, the machining stress values cannot be directly summed to volumetric residual stresses due to the very different depths at which they act, as they penetrate typically up to 0.2 mm depth from the surface [21,22]. The effect of MIRS is introduced similarly as with BIRS, by discretizing the depth affected by the thermomechanical loads during the machining process, being k ij the distance of the center of gravity of each of the sublayers (i) to the center of gravity of the whole part cg for each process step ( j) after a layer is removed.…”

“…This showed that BIRS led to the bending deformation of the whole workpiece, while MIRS of the rib or web caused a net twisting deformation. One investigation in Al 7050-T7451 revealed that BIRS are the main effect of MD of thin-walled plates [22]. On the contrary, under different processing conditions the same material experienced, below a critical depth, that MIRS were the primary contributor [23].…”

A new approach to deformation control of aeronautical monolithic components of aluminum alloy plates based on stress inverse and stress evaluation

“…实际加工中, 由于高速切削比常规切削的切削力 减小约30% [12] , 产生的加工应力只存在于很薄的一层 内, 且时间短暂, 对初始残余应力的影响非常小, 从而 对最终的加工变形影响也非常小. 毛坯的初始残余应 力对零件变形起着决定性作用, 其贡献率高达90%以 上 [13] . 由此可见, 零件变形完全可以忽略加工过程中 产生的附加应力而仅受毛坯初始残余应力的影响 [14] .…”

The Metal Surface Layer Mechanical Condition Transformation in Machining Processes

“…Currently, the surface layer (SL) predominant role in ensuring the machine parts durability is generally recognized [1][2][3][4][5][6][7][8][9][10][11][12][13]. Especially the part surface layer, which forming throughout the manufacture technological process, receives the greatest loading during operation.…”