Abstract
During the machining of aerospace thin-walled components, a large amount material is removed, and machining-induced residual stress is induced in the boundary layer of the work piece, which results in deformation of the components. In this study, the effects of material initial residual stress and machining-induced residual stress on the deformation of aluminium alloy plate are studied. A theoretical model of the plate is analysed first, and the experiments of the milling deformation under different initial residual stress conditions are performed. The results show that the machining-induced residual stress is the primary factor of distortion. The coupling action of compressive initial residual stress and machining-induced residual stress increase the plate deformation, and the coupling action of tensile initial residual stress and machining-induced residual stress decrease the plate deformation. The finite element simulation results are compared with experimental results and found to be in good agreement.
Highlights
With increasing demand for the improvement of airplane performance, large monolithic components are widely used in order to reduce airplane weight in the aviation industry [1]
Aircraft parts are typically machined from prestretched 7050-T7451 aluminium alloys
In order to reduce the initial residual stresses and increase mechanical strength, pre-treatments are performed in producing blank plates, i.e. quenching, extrusions, stretching, etc. [2] and [3]
Summary
With increasing demand for the improvement of airplane performance, large monolithic components are widely used in order to reduce airplane weight in the aviation industry [1]. During the machining process of structural components, up to 90% of the material is removed from the blank. For those components, it is easy to cause substantial distortion because of the initial residual stress and machininginduced residual stress. In order to reduce the initial residual stresses and increase mechanical strength, pre-treatments are performed in producing blank plates, i.e. quenching, extrusions, stretching, etc. Machining-induced residual stress is produced on the machined surface of the work piece due to the action of machining
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More From: Strojniški vestnik – Journal of Mechanical Engineering
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