Prediction of Shape Deviations in Face Milling of Steel

Gulpak, Maxim; Sölter, Jens; Brinksmeier, E.

doi:10.1016/j.procir.2013.06.058

Cited by 30 publications

(17 citation statements)

References 16 publications

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“…Therefore XFEM was used, which is a more efficient method, since it enriches the shape functions in order to model discontinuities along material interfaces. For evaluating the efficiency of the proposed method a typical aerospace part was used and the results were in accordance to state of the art [7][8][9][10][11].…”

Section: Discussionmentioning

confidence: 99%

See 1 more Smart Citation

Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

D’Alvise¹,

Chantzis²,

Schoinochoritis³

et al. 2015

Procedia CIRP

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Metallic parts for the aeronautics industry are usually manufactured by material subtraction using machining processes. The gradual relaxation of the bulk material residual stresses during machining causes distortion in the final part. When modelling a multi-pass machining process, in order to predict distortion, the classical finite element method, using conforming meshes, faces limitations in flexibility and accuracy. Cutting paths cannot match the work-piece mesh before the simulation, since they are defined in the initial geometry and not in a deformed one. As a result, re-meshing is required between two machining passes. In order to circumvent these limitations, an innovative approach based on the level-set method has been developed in order to define cutting paths independently of the work-piece mesh. The proposed approach is applied to simulating milling of an airfoil.

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Section: Discussionmentioning

confidence: 99%

“…In [9] a hybrid model consisting of 3 sub-models was developed. Each of the 2 sub-models consisted of a linear regression model and a finite element model.…”

Section: Introductionmentioning

confidence: 99%

Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

D’Alvise¹,

Chantzis²,

Schoinochoritis³

et al. 2015

Procedia CIRP

View full text Add to dashboard Cite

show abstract

“…With SHPB tests at different temperatures, thermal softening exponent can be identified with GA or least square approximation (LSA) technique, setting the target function as equation (4). In all the tests, the strain and strain rate should be fixed as constants, e c and _ e c…”

Section: Combined Identification Methods For Parameters In J-c Modelmentioning

confidence: 99%

“…[1][2][3] Moreover, residual stress is a key factor influencing the machining-induced deformation of thinwalled structures. 4 Thus, it is important to accurately predict and effectively control the machining-induced residual stress.…”

Section: Introductionmentioning

confidence: 99%

Finite element method study on the influence of initial stress on machining process

Feng

et al. 2015

Advances in Mechanical Engineering

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Machining-induced residual stress has significant influence on the performance of the parts. Extensive studies about machining-induced residual stress concerning many factors have been carried out but few focused on the role of initial stress distribution in cutting process. In this study, a finite element method study on the influence of initial stress on machining process is carried out. A combined method to obtain the parameters in Johnson-Cook constitutive model was introduced and verified with face milling experiments and finite element method simulations. And with this carefully established finite element method model, the influence of the value and distribution range of initial stress on cutting process was studied. The results show that the initial tensile stress makes the cutting stress distribution within the workpiece become more tensile and diminishes the cutting forces and tool tip temperature, while initial compressive stress has opposite effects. The value and distribution range of initial stress determines the strength of this influence. On the other hand, the machining process also results in the partial release of initial stress in the bulk material.

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“…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.…”

Section: Introductionmentioning

confidence: 99%

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

Aurrekoetxea

Lacalle²,

Llanos

2020

Materials

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Prediction and control of machining distortion is a primary concern when manufacturing monolithic components due to the high scrap and rework costs involved. Bulk residual stresses, which vary from blank to blank, are a major factor of machining distortion. Thus, a bulk stress characterization is essential to reduce manufacturing costs linked to machining distortion. This paper proposes a method for bulk stress characterization on aluminium machining blanks, suitable for industrial application given its low requirements on equipment, labour expertise, and computation time. The method couples the effects of bulk residual stresses, machining stresses resulting from cutting loads on the surface and raw geometry of the blanks, and presents no size limitations. Experimental results confirm the capability of the proposed method to measure bulk residual stresses effectively and its practicality for industrial implementation.

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Prediction of Shape Deviations in Face Milling of Steel

Cited by 30 publications

References 16 publications

Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

Finite element method study on the influence of initial stress on machining process

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

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