Machining Distortion for Thin-Walled Superalloy GH4169 Caused by Residual Stress and Manufacturing Sequences

Zhu, Pingzhong; Liu, Zhanqiang; Ren, Xiaoping; Cai, Yukui

doi:10.3390/met12091460

Cited by 11 publications

(6 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, thermal-induced warpage caused distortion. In addition, the target tool path could not be completed, and the target area could not be fully machined due to the fact of unwanted conditions, such as chatter vibration [22]. Therefore, the machined parts were scanned again.…”

Section: Measurement Strategymentioning

confidence: 99%

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

2023

View full text Add to dashboard Cite

Wire and arc additive manufacturing (WAAM) technology has recently become attractive due to the fact of its high production capacity and flexible deposition strategy. One of the most prominent drawbacks of WAAM is surface irregularity. Therefore, WAAMed parts cannot be used as built; they require secondary machining operations. However, performing such operations is challenging due to the fact of high waviness. Selecting an appropriate cutting strategy is also challenging, because surface irregularity makes cutting forces unstable. The present research determines the most suitable machining strategy by assessing the specific cutting energy and local machined volume. Up- and down-milling are evaluated by calculating the removed volume and specific cutting energy for creep-resistant steel, stainless steel, and their combination. It is shown that the main factors that affect the machinability of WAAMed parts are the machined volume and specific cutting energy rather than the axial and radial depths of the cut due to the fact of high surface irregularity. Even though the results were unstable, a surface roughness of 0.1 µm was obtained with up-milling. Despite a two-fold difference in the hardness between the two materials in the multi-material deposition, it is found that hardness should not be used as a criterion for as-built surface processing. In addition, the results show no machinability difference between multi- and single-material components for a low machined volume and low surface irregularity.

show abstract

Section: Measurement Strategymentioning

confidence: 99%

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

2023

View full text Add to dashboard Cite

show abstract

“…The residual stress profile induced by ball-end milling conventionally follows a similar pattern [34], as shown in Figure 7. This expression [23] is given by Eq. ( 11).…”

Section: Hyperbolic Tangent Modelmentioning

confidence: 99%

“…A multiobjective particle swarm optimization procedure was employed in optimizing process parameters. Zhou [23] proposed to use the hyperbolic tangent function to characterize the cutting residual stress field of titanium alloys. He combined an intelligent optimization algorithm and polynomial interpolation method to establish the mapping relationship between process parameters and residual stress distribution model coefficients.…”

Section: Introductionmentioning

confidence: 99%

Hybrid prediction model for residual stress profile induced by multi-axis milling Ti-6Al-4 V titanium alloy combined finite element with experiment

Wang

Zhou

Ren

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Complex curved thin-walled structures, mainly using multi-axis milling, are highly susceptible to deformation induced by residual stress. It is therefore that there is a considerable amount of researches on developing predictive models for machining-induced residual stress. However, these developed models for residual stress prediction mainly focus on turning and threeaxis milling. For multi-axis milling, a hybrid model combining experimental results and finite element(FE) model is established to predict the residual stress profile of Ti-6Al-4V titanium alloy in the current study. Based on the experimental and simulated results, the residual stress profile is fitted by the hyperbolic tangent function using the firefly algorithm (FA). Good fitting accuracy is obtained, which the R 2 values change from 85.3% to 99.1% in the σx direction and change from 80.7% to 98.1% in the σy direction. The radial basis function (RBF) neural network is used to establish the relationship between the coefficients of hyperbolic tangent model and the milling parameters. The prediction accuracy is verified to achieve 92.7% and 91.4% in the σx and σy directions, respectively. The effects of cutting speed, feed rate, and inclination angle on surface residual stress and influence depth are investigated. The results show that there is a strong nonlinear relationship between the surface residual stress and milling parameters. The proposed hybrid prediction model of residual stress can be used for further machining optimization of complex curved thin-walled structures.

show abstract

“…Therefore, large internal stress and insufficient dimensional accuracy are found in the cold-forming process [5]. To eliminate internal stress, cold-forming parts require to be annealed and then reshaped with a long production cycle and low qualification rate for parts [6]. There is a significant improvement in plasticity and forming limit at high temperatures with lower working hardening and spring back [7].…”

Section: Introductionmentioning

confidence: 99%

Hot deformation behavior and physical-based constitutive modelling under plane-stress state for Nickle-based superalloy sheets

Wu,

Chen,

Bao

et al. 2024

Preprint

View full text Add to dashboard Cite

Forming limit curves at high temperatures under plane stress states is beneficial for guiding the process parameter design of hot forming superalloy sheets. Constrained by the high deformation temperatures, the establishment of FLCs of superalloy sheet at high temperatures are extremely diffiuclt. This paper conducts an experimental and modelling research establish the physical based model with the accurate prediction of hot flow behavior as well as micro grain sizes, using which, the forming limit curves can be predicted. First, the uniaxial tensile tests under different temperatures and strain rates and EBSD observations of typical conditions were conducted to obtain the hot flow behavior and grain evolution. Second, the dome test at room temperature was performed, and corresponding simulation was further carried out to obtain the forming limit at room temperature under plane stress states. Using the above results, a plane-stress constitutive model for GH3128 superalloy was established enabling plane-stress test results under typical hot conditions to be accurately predicted. The prediction accuracy of hot uniaxial and biaxial stretching results are 94.2% and 95.4%, respectively.

show abstract

Machining Distortion for Thin-Walled Superalloy GH4169 Caused by Residual Stress and Manufacturing Sequences

Cited by 11 publications

References 21 publications

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

Hybrid prediction model for residual stress profile induced by multi-axis milling Ti-6Al-4 V titanium alloy combined finite element with experiment

Hot deformation behavior and physical-based constitutive modelling under plane-stress state for Nickle-based superalloy sheets

Contact Info

Product

Resources

About