Prediction of the Distortions Caused by the Redistribution of the Residual Stresses During Machining Using FEM

Abstract

Aeronautic parts have generally complex structure and need high mechanical properties. Machining is an essential step to manufacture aluminium alloy aeronautical parts. To obtain parts complying with geometrical specifications, the machining process must be well understood and mastered. Indeed, many factors may induce geometrical deflections during the machining process. On large aeronautical parts, the main factor which can lead to non-complying part is the unexpected release of original residual stresses. In this work, a specific finite element solver has been developed to predict the distortion due to the redistribution of the original residual stresses during machining. Then, results obtained are compared with experimental tests to validate this approach.