Part Distortion Modeling on Aluminum Slender Structural Components for Aeronautical Industry

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

“…This way, the flatness of the raw specimen during the process is ensured. In contrast to other works [16][17][18]25,28], the raw specimen is not presumed totally flat when no material is removed ( Figure 2). Thus, the clamping force is responsible for flattening the specimen, enabling the removal of constant thickness layers.…”

“…In order to evaluate the work once stress data and geometry are known, the proposed formulation can be employed to simulate the machining process and predict distortion as material is removed [16,25].…”

“…A grid of 8 x 4 points was measured with a distance ( ) of 40 mm. The curvature , was obtained fitting these measurements for each ( ) layer by least-squares regression to a quadratic surface function through Equations (15), (16), and (17). The torque used in all clamping points and ( ) sequences was measured and limited to 35 Nm.…”

“…In order to face this problem, some authors proposed modified techniques for measuring BIRS based on the traditional methods and show potential to overcome some of the limitations aforementioned. Amongst them, on-machine layer removal can be highlighted [16][17][18], due to its potential for industrial implementation. The traditional layer-removal method is time-consuming as it requires strain gauges to be repeatedly glued and removed.…”

“…Furthermore, the modified formulation, makes it possible to leave the ribs unmachined [16]. Thereby, it becomes a quasi-non-destructive measuring technique, thus, the characterized blanks are still usable to machine the final component geometry.…”