Abstract
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.
Highlights
Machining distortion (MD) remains a costly issue within the aerospace industry, especially for monolithic and thin-walled parts, for which up to 90% of the material is removed [1]
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
The final distortion comes from a combination of different sources such as bulk or blank-initial residual stresses (BIRS), machining-induced residual stresses (MIRS), thermal deformation due to heat generation during machining, and deformation caused by clamping and other process forces, as it was reported by Brinksmeier et al [2]
Summary
Machining distortion (MD) remains a costly issue within the aerospace industry, especially for monolithic and thin-walled parts, for which up to 90% of the material is removed [1]. In the case of aluminium alloys, some authors [3,4,5,6] reported that the main cause for MD lies in the redistribution of the BIRS profile after the material is removed and a new equilibrium is reached. Even in cases at which machining blanks are stress relieved treated, BIRS are still a major source of distortion due to the high asymmetry of aerospace monolithic components with thin walls and webs. The final distortion comes from a combination of different sources such as bulk or blank-initial residual stresses (BIRS), machining-induced residual stresses (MIRS), thermal deformation due to heat generation during machining, and deformation caused by clamping and other process forces, as it was reported by Brinksmeier et al [2].
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