Predicting Surface Residual Stress for Multi-Axis Milling of Ti-6Al-4V Titanium Alloy in Combined Simulation and Experiments

Wang, Zongyuan; Zhou, Jinhua; Ren, Junxue; Shu, Ailing

doi:10.3390/ma15186471

Cited by 9 publications

(5 citation statements)

References 28 publications

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“…Table 4 lists the simulation arrangements for the implementation and analysis of the current study. The simulation of residual stress can be divided into four basic processes [23]: machining -cutting backtransformation constraints -cooling. Firstly, the cutting tool was set to complete the milling process according to the given cutting parameters.…”

Section: Cutting Process and Residual Stress Data Extractionmentioning

confidence: 99%

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Finite element simulation of residual stress in milling of aluminum alloy with different passes

Xu,

Yue,

Chen

et al. 2023

Int J Adv Manuf Technol

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Machining-induced residual stress is an important measure of surface integrity. Better residual stress distribution will improve the quality and performance of the workpiece. In the process of cutting, it often encounters the situation of multi-pass cutting. The formation of residual stress in the process of singleor multi-pass cutting has been widely studied, but few researchers consider the same total radial cut depth, divided into single-pass cutting and multi-pass cutting, and the last cutting in the process of multipass cutting is less studied. The difference between single-pass cutting and multi-pass cutting is that the former machining of cutting is used as the initial state of the latter machining. The stress/strain and temperature generated on the surface of the former machining can affect the subsequent cutting force, temperature, plastic deformation, and the nal residual stress. This paper studies the distribution of cutting force and residual stress generated by single-and multi-pass cutting of Al-7075-T6, and focuses on the analysis of the multi-pass cutting strategy. The three-dimensional nite element method is used to simulate and the experimental results are in good agreement with the simulation results. The results show that compared with single-pass cutting, multi-pass cutting can reduce the surface tensile stress and the magnitude and depth of underground residual compressive stress, and the effect of decreasing method is more obvious when multi-pass cutting. The last machining is affected by the previous cutting. When the next radial cutting depth is greater than the plastic deformation depth produced by the previous cutting, the next radial cutting depth is the same, and the trend of residual stress is approximately the same. The results can guide the optimization of residual stress in the multi-pass cutting strategy.

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Section: Cutting Process and Residual Stress Data Extractionmentioning

confidence: 99%

“…Simulation data extraction [23]. Comparison of residual stress on the surface of experiment and simulation under the different cases.…”

Section: Figuresmentioning

confidence: 99%

Finite element simulation of residual stress in milling of aluminum alloy with different passes

Xu,

Yue,

Chen

et al. 2023

Int J Adv Manuf Technol

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show abstract

“…Liu et al [8] used FE to analyze the effect of tool geometry on residual stresses in orthogonal machining of Inconel 718 alloy. Wang et al [9] established a hybrid model combining experimental results and FE model to predict the residual stress profile of TC4 alloy for multi-axis milling. Jiang et al [10] use simulation and experiments to analyze the nonlinear relationship induced by cutting force and heat.…”

Section: Introductionmentioning

confidence: 99%

Empirical modeling of residual stress profile for multi-axis milling GH4169G

Zhou,

Zhang,

Liu

et al. 2024

Preprint

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The superalloy GH4169G is used to manufacture integral blisks for aero engines. Torsional bending deformation caused by residual stresses from multi-axis machining is one of the major factors contributing to excessive dimensional errors in blisk blade manufacturing. However, few studies have focused on predicting the residual stress profile in multi-axis milling of the superalloy GH4169G. Therefore, in this paper, an empirical model was established to predict the residual stress profile in multi-axis milling of the superalloy GH4169G. First, 36 sets of multi-axis milling experiments were conducted. Then, the residual stress profile was fitted using the Exponential Decay Cosine (EDC) function and the Firefly algorithm (FA) based on the experiment. Support Vector Machine (SVM) was used to establish the mapping relationship between the process parameters and the coefficients of the EDC function. In addition, the effects of process parameters including spindle speed, feed per tooth and tilt inclination angle on surface residual stress, maximum compressive residual stress and residual stress depth were investigated. Finally, the NSGA-III algorithm was used to obtain the recommended process parameters for multi-axis milling of the superalloy GH4169G blades.

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“…Therefore, thin-walled structures are applied due to the characteristics of lightweight and compact structures. However, it is easy to deform as a result of the low rigidity performance of thinwalled structures under the condition that cutting force, cutting heat, and clamping force during machining [1,2] . After the force balance is broken, the deformation of parts is caused by the redistribution of the internal stress [3] , which generates high residual stress.…”

Section: Introductionmentioning

confidence: 99%

The Residual Stress Control of Thin-walled Sleeve Parts with Weak Rigidity

Tian,

Sun,

et al. 2023

J. Phys.: Conf. Ser.

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Photoelectric products in the military industry tend to be lightweight in design, requiring the part to be lightweight and have high specific strength. As one of the structural parts of photoelectric products, the thin-walled sleeve part has the peculiarity of lightweight and thin wall thickness. Nevertheless, the residual stress during machining processing poses an adverse effect on the accuracy of the parts. In this paper, the influence of residual stress on the accuracy of the parts during the processing was studied. Before fine machining, the residual stress was reduced by artificial aging techniques and ultrasonic beam control methods. Finally, the effect of the two stress relief methods was evaluated according to the qualified rate of the processing accuracy of the parts. The research results show that the axial residual stress of the part is larger than the circumferential residual stress. Both artificial aging techniques and ultrasonic beam control can eliminate residual stress, and the ultrasonic beam control method is more targeted and uniform.

show abstract

Predicting Surface Residual Stress for Multi-Axis Milling of Ti-6Al-4V Titanium Alloy in Combined Simulation and Experiments

Cited by 9 publications

References 28 publications

Finite element simulation of residual stress in milling of aluminum alloy with different passes

Finite element simulation of residual stress in milling of aluminum alloy with different passes

Empirical modeling of residual stress profile for multi-axis milling GH4169G

The Residual Stress Control of Thin-walled Sleeve Parts with Weak Rigidity

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