Residual stress distribution caused by milling

Elkhabeery, M. M.; Fattouh, M.

doi:10.1016/0890-6955(89)90008-4

Cited by 88 publications

(38 citation statements)

References 4 publications

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“…It is well-known (Fattouh and El-Khabeery, 1989) that the generated zone with beneficial residual stresses after burnishing covers only the surface layers. One of the most used experimental methods for measurement of residual stresses is the x-ray diffraction (Webster and Ezeilo, 2001).…”

Section: Nature Of the Employed Methodsmentioning

confidence: 99%

“…Deflection etching technique is based on removal of thin layers of stressed material from the machined surface region by electrochemical action (Sadat, 2012). This method was first developed by Frisch and Tompsen (1951) and later was used by many researchers (Sadat and Bailey, 1985;Fattouh and El-Khabeery, 1989;El-Khabeery and Fattouh, 1989;El-Axir, 2000Belgasim and El-Axir 2010).…”

Section: Nature Of the Employed Methodsmentioning

confidence: 99%

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Enhancement of fatigue life of rail-end-bolt holes by slide diamond burnishing

Maximov¹,

Duncheva²,

Anchev³

et al. 2014

10.5267/j.esm

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The fatigue failure around rail-end-bolt holes is particularly dangerous since it leads to derailment of trains and consequently to inevitable accidents. It is well-known that the fatigue life of structural holed components, subjected to cyclic load, can be increased by generating compressive hoop stresses around the holes. These beneficial residual compressive stresses significantly reduce the maximum values of the operating tensile stresses arising at the critical points of the components and thus impede the formation of first mode cracks. A new approach to enhancement of fatigue life of rail-end-bolt holes has been developed. The approach involves sequential drilling and reaming through a new combined tool and then slide diamond burnishing by a new device. The technology implementation was carried out on machine tool. The process of creating residual stresses has been studied both experimentally and numerically. The experimental study was conducted by means of a modified split ring method. A reliable finite element modeling approach to the slide diamond burnishing process was developed. On this basis, the process was optimized by means of a genetic algorithm. As a result, the optimal combination of the governing process parameters is established, which ensures both maximum depth of the compressive zone and maximum absolute values of the residual stresses.

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Section: Nature Of the Employed Methodsmentioning

confidence: 99%

Section: Nature Of the Employed Methodsmentioning

confidence: 99%

Enhancement of fatigue life of rail-end-bolt holes by slide diamond burnishing

Maximov¹,

Duncheva²,

Anchev³

et al. 2014

10.5267/j.esm

View full text Add to dashboard Cite

show abstract

“…Machining operations would generate geometric distortions and a high level of surface residual stresses, which has been studied extensively in terms of machining techniques (El-Khabeery and Fattouh, 1989;Rao and Shin, 2001; Ee et al, 2005;Ulutan et al, 2007;Denkena et al, 2008;Tang et al, 2009) but has not yet been considered in springback predictions for CAF. The machined plate normally contains different thickness at different sections.…”

Section: Introductionmentioning

confidence: 99%

“…These residual stress profiles can be affected by the individual influence of, or interactions amongst, machining parameters (El-Khabeery and Fattouh, 1989), cutting temperature (Ulutan et al, 2007), boundary and loading conditions (Denkena et al, 2008), as well as the cutting tool's material (Rao and Shin, 2001), geometry (Ee et al, 2005) and even its degree of wear (Tang et al, 2009 …”

Section: Introductionmentioning

confidence: 99%

Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming

Lam

Shi

Lin

et al. 2015

International Journal of Mechanical Sciences

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Abstract. Springback behaviour of surface-machined 7B04-T651 aluminium plates of 3 to 8 mm thicknesses, creep-age formed under a single curvature bending radius of 1200 mm, has been experimentally investigated. The surface residual stress levels of the plates have been measured and the typical residual stress distribution and values in 7000-series aluminium alloys have been reviewed and analysed. Finite element models have been developed to simulate creep-age forming (CAF) processes and predict the amount of springback in the physical CAF test. Machining-induced residual stresses and distortion have been considered in the finite element models. This paper presents a first attempt to study the effect of machining-induced residual stresses on the errors of springback prediction in CAF of 7000-series aluminium alloy panel components. It has been found that the effect of machininginduced residual stresses on the accuracy of springback prediction is related to the initial loading stress levels in CAF. In addition, when the initial distortion conforms to the loading curvature, an opposing effect on the material's deformation is observed. Creep-ageing material constant related to effective creep strain rate.1 Creep-ageing material constant related to rate of age hardening.2 Creep-ageing material constant related to the depletion of solute into precipitate.3 Creep-ageing material constant related to rate of precipitate growth.4 Creep-ageing material constant controlling the effect of dislocation density (or creep) on precipitate nucleation and growth.5 Creep-ageing material constant related to rate of dislocation density.Creep-ageing material constant related to rate of dislocation hardening.Bending radius of forming tool.̅ , ̅ Normalised precipitate size and its rate term respectively. ̅ 0 Initial value for normalised precipitate size.Radius of revolvement of workheads of the flexible form tool.Creep-ageing time.1 , 2 , 3 , 4 Time of loading, heating, cooling and unloading respectively. Artificial ageing time.Solution heat treatment time., , Translational degrees of freedom in Cartesian coordinates., , Rotational degrees of freedom in Cartesian coordinates.Poisson's ratio., , Cartesian coordinates., positions of the lower and upper splines respectively.

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“…Residual stresses in milling tend to be compressive in the machined surface [2,6]. In grinding, residual stresses are dominantly tensile at the surface, which is followed by low values of compressive stresses deeper into the material [2,7].…”

Section: Introductionmentioning

confidence: 99%