Milling induced residual stresses in structural parts out of forged aluminium alloys

Denkena, Berend; León, Luis de

doi:10.1504/ijmmm.2008.023717

Cited by 21 publications

(13 citation statements)

References 4 publications

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“…According to residual stresses obtained results, for flank milling technique it was appreciated a tensile residual stress near to machined surface common for this technique [ 46 ]. On the contrary, flank SAM measurements showed a compressive pattern residual stress near to the manufactured surface.…”

Section: Resultsmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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Thermoresistant superalloys present many challenges in terms of machinability, which leads to finding new alternatives to conventional manufacturing processes. In order to face this issue, super abrasive machining (SAM) is presented as a solution due to the fact that it combines the advantages of the use of grinding tools with milling feed rates. This technique is commonly used for finishing operations. Nevertheless, this work analyses the feasibility of this technique for roughing operations. In order to verify the adequacy of this new technique as an alternative to conventional process for roughing operations, five slots were performed in Inconel® 718 using flank SAM and flank milling. The results showed that flank SAM implies a suitable and controllable process to improve the manufacture of high added value components made by nickel-based superalloys in terms of roughness, microhardness, white layer, and residual stresses.

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Section: Resultsmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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“…Besides the contact zone, the model concept includes the measuring stand components having a bearing on the accuracy and quality of identifying deformations. The full 3D model reproduces the components of the test stand developed by the authors and described in [15,16]. The following are modelled: a table, a milled rectangular specimen (made of 5083 aluminium alloy) whose top surface roughness is known, a steel punch ending in a short quadratic prism (ground and polished, with a 1 mm  1 mm square cross section), and a contact zone together with a subsurface zone, constituting the principal part of the model (Fig.…”

Section: D Model Conceptmentioning

confidence: 99%

“…Such changes can be due to specimen surface hardening and permanent deformations during machining as well as during the first loading of the specimen. In the literature on the subject [16,17] it is reported that in the case of aluminium alloy milling the residual stresses accompanying this strain hardening can reach deep into the material (as deep as 100-300 μm).…”

Section: Impact Of Subsurface Zone Materials Properties On Contactmentioning

confidence: 99%

Evaluation of different approaches to 3d numerical model development of the contact zone between elementary asperities and flat surface

Maciołka

Jędrzejewski

2017

Journal of Machine Engineering

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This paper presents two triaxial finite element (FE) models: a “full model” and a “quarter model”, representing the contact between the specimen’s rough surface and the ideally smooth and flat surface of the punch. Models have a contact zone that represents the topography of the real surface and has elastoplastic properties close to those of the real contact. The contact zone was entirely modelled on the basis of roughness measurements performed on a real milled specimen made of 5083 aluminium alloy. The development of the FE models, the stages in their refinement and the interlinking of the contact zone with the material of the specimen are described. The results of the computed deformations occurring during the specimen contact loading with the punch were compared with the experimental results. The possible causes of the observed deviations of the computer simulation results from the experimental ones were discussed. The models were used to analyse the effect of the specimen’s material properties, i.e. Young’s modulus, yield strength, compressive strength and material hardening, on the deformations in the contact. On this basis a procedure for predicting the parameters describing the contact characteristic in cases of changes in the properties of the subsurface zone is proposed

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“…It noteworthy that, in this case, the study of the residual stress left in the machined surface was limited to the tangential stress component in the cutting direction. Recently, Denkena and De Leon [14] studied the influence of cutting parameters and tool geometry on the level of residual stresses induced by milling in workpieces of forged aluminium alloys. More recently, Díaz et al [15,16] and Mammana et.…”

Section: Related Workmentioning

confidence: 99%

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Díaz¹,

Mammana²,

Guidobono³

2012

MME

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In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.

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Milling induced residual stresses in structural parts out of forged aluminium alloys

Cited by 21 publications

References 4 publications

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

Evaluation of different approaches to 3d numerical model development of the contact zone between elementary asperities and flat surface

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

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