Residual Stresses in High Speed Turning of Thin-Walled Cylindrical Workpieces

Brinksmeier, E.; Heinzel, Carsten; Garbrecht, M.; Sölter, Jens; Reucher, Griet

doi:10.20965/ijat.2011.p0313

Cited by 13 publications

(5 citation statements)

References 13 publications

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“…This was not expected since the process should be mechanically dominant and result in predominant compressive residual stresses as is documented in Ref. . It was therefore assumed that although the specimens were normalised before and after premachining, residual stresses could not be reduced to a level where they do not influence the machining results regarding shape deviations.…”

Section: Resultsmentioning

confidence: 96%

“…This can be attributed to the comparatively small spread between the upper and lower levels of the machining parameters which were selected in a way that all possible combinations stay within the manufacturer recommended range and ensure a stable process. Still, from literature it is known that a variation of the cutting parameters in a broader range leads to a distinct change of the residual stress state of the machined workpiece . Nevertheless, a significant effect can be observed from the variation of the width of cut a e .…”

Section: Resultsmentioning

confidence: 99%

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Development of a hybrid model for the prediction of shape deviations in milling

Gulpak

Sölter

2016

Materialwissenschaft Werkst

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The productivity in machining of high precision components is limited among others by the achievable geometric accuracy. Shape deviations arise due to several mechanisms of which residual stresses and a varying material removal due to thermal expansion have been incorporated in a proposed hybrid model. The model is based on two initially separated sub models which require a set of experimentally obtained input parameters. Both sub models utilize the finite element method. Sub model 1 calculates the mechanic response of the workpiece loaded with a near surface residual stress field (source stresses) resulting from the interaction of tool and workpiece. Sub model 2 calculates the thermal expansion of the workpiece utilising a three-dimensional simulation of a moving surface heat source. The resulting inhomogeneous material removal is superimposed with the calculated shape deviations from sub model 1. This work focuses on distortion caused by machining induced residual stresses which are modelled as source stresses (sub model 1). These so called source stresses can be calculated directly from the bending and torsion of machined specimens and represent the distortion potential of the face milling process. The results demonstrate a pronounced correlation between the obtained source stresses and the width of cut a e . They further indicate that a separation of the effects resulting from the removal of material containing workpiece inherent residual stresses and from the newly generated residual stresses in the machined surface layer is required for the calculation of machining induced residual stresses.In der spanenden Bearbeitung von Hochpräzisionskomponenten ist die Produktivität u. a. durch die geforderten Maß-und Formtoleranzen begrenzt. Formabweichungen, welche die Toleranzen überschreiten können, entstehen dabei aufgrund unterschiedlicher Mechanismen, von denen zwei, die Entstehung von Eigenspannungen und der ungleichmäßige Materialabtrag durch thermische Dehnungen, in dem vorgeschlagenen Hybridmodell berücksichtigt werden. Das Hybridmodell basiert auf zweien zunächst getrennten Submodellen, welche mithilfe von Zerspanexperimenten parametriert werden. Die Berechnung erfolgt mit der Methode der Finiten Elemente. Im Submodell 1 wird die mechanische Antwort des Werkstücks auf bearbeitungsinduzierte Eigenspannungen (Quellspannungen) berechnet, welches aus randschichtnahen plastischen Verformungen des Bearbeitungsprozesses resultiert. Im Submodell 2 werden thermische Dehnungen des Werkstücks in einer dreidimensionalen FE-Simulation einer bewegten Wärmequelle berechnet. Der daraus resul-

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Section: Resultsmentioning

confidence: 96%

Section: Resultsmentioning

confidence: 99%

Development of a hybrid model for the prediction of shape deviations in milling

Gulpak

Sölter

2016

Materialwissenschaft Werkst

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“…Cutting speed [8], cutting depth [9]and feed rate [10] have a critical impact on residual stress. Ekkard et al [11] concluded that in turning thin walls of AISI 52100 steel, feed rate plays the most important effects on turning surface residual stress, then speed, wall thickness and lastly depth of cut. Turning tool and workpiece hardness are also factors affecting residual stress [12].…”

Section: Introductionmentioning

confidence: 99%

Effects of multi-pass turning on surface properties of AISI 52100 bearing steel

Xue

Zhang

et al. 2023

Int J Adv Manuf Technol

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Hard turning is extensively used in the machining of bearings. The turning process has a significant influence on the properties of machined surface. In this paper, multi-pass turning experiments were machined on AISI 52100 bearing steel, and corresponding simulation model was established. The effects of multiple pass turning on micro hardness and residual stress were investigated. The results demonstrate that the machined surface hardness of single, double and triple pass turning is 30.0%, 25.2% and 24.5% higher than the initial surface, respectively, at a turning depth of 0.1mm and a speed of 100m/min. Double pass turning significantly reduces the residual stress of machined surface. With the change of turning speed, the residual stress after double pass turning is 88 MPa lower than single pass on average, while the difference of residual stress is relatively minor after double pass and triple pass turning. At a cutting depth of 0.05 mm, the residual stresses after double pass turning and triple pass turning are 152 MPa lower than those after one-pass turning. As the turning depth increases, the influence of the previous pass turning gradually decreases in terms of residual stress.

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“…The reasons are that material loads occurring during the machining process in the form of displacements and strains, which are responsible for the material modifications, cannot be measured and that a lack of the process knowledge exists. Therefore, the targeted material modifications are only adjusted via the machining parameters or process variables of the machine tools in an iterative way [4,5,6]. Remedy can be provided by the introduced concept of process signatures [7], which focuses on the internal mechanisms and the influencing quantities [8] leading to the material change to describe the workpiece modification.…”

Section: Introductionmentioning

confidence: 99%

In-Process Measurement of Three-Dimensional Deformations Based on Speckle Photography

Tausendfreund¹,

Stöbener²,

Fischer³

2021

Preprint

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In the concept of the process signature, the relationship between a material load and the modification remaining in the workpiece is used to better understand and optimize manufacturing processes. The basic prerequisite for this is to be able to measure the loads occurring during the machining process in the form of mechanical deformations. Speckle photography is suitable for this in-process measurement task and is already used in a variety of ways for in-plane deformation measurements. The shortcoming of this fast and robust measurement technique based on image correlation techniques is that out-of-plane deformations in the direction of the measurement system cannot be detected and increases the measurement error of in-plane deformations. In this paper, we investigate a method that infers local out-of-plane motions of the workpiece surface from the decorrelation of speckle patterns and is thus able to reconstruct three-dimensional deformation fields. The implementation of the evaluation method enables a fast reconstruction of 3D deformation fields, so that the in-process capability remains given. First measurements in a deep rolling process show that dynamic deformations underneath the die can be captured and demonstrate the suitability of the speckle method for manufacturing process analysis.

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Residual Stresses in High Speed Turning of Thin-Walled Cylindrical Workpieces

Cited by 13 publications

References 13 publications

Development of a hybrid model for the prediction of shape deviations in milling

Development of a hybrid model for the prediction of shape deviations in milling

Effects of multi-pass turning on surface properties of AISI 52100 bearing steel

In-Process Measurement of Three-Dimensional Deformations Based on Speckle Photography

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