The Effect of Quench-Induced Residual Stresses on the Distortion of Machined Thin-Walled Parts

Abstract

In the heat treatment process, during the quenching of aluminum alloy, a high level of residual stresses is observed due to the severe thermal gradient at the surface and center of the work piece, which acts as the main source of distortion in machined parts. This article attempts to investigate the correlation between quench-induced residual stresses and the distortion of thin-walled parts during machining. The effects of polymer and uphill quenching methods in comparison with water quenching in the reduction of residual stresses are investigated on an experimental basis. By conducting the machining tests, the effects of residual stress on distortion and the effect of material removal in machining on stress redistribution are investigated. The results indicate that by adopting the polymer quenching method, the level of residual stress and distortion can be reduced significantly. According to the results, material removal in machining causes an imbalance in the compressive and tensile stresses, leading to a redistribution of the stress and distortion.