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.

No abstract

No abstract

No abstract

No abstract

No abstract

No abstract

Machining of slender components in aluminum and titanium presents major difficulties in terms of geometry and dimensional requirements. During the machining of this type of components, non-conformances due to distortions are frequent due to the residual stresses in the bulks, together with the machining induced stresses on the surfaces. Currently it is common to find numerical models based on finite element software that can estimate the final distortion of the component after machining. These calculations are key when trying to adapt the machining process to obtain components free of distortions. Despite representing a move forward, these finite element models have limitations in their industrial applicability due to the long computational times and poor usability. The present work introduces an analytical simulation model of a machining process, similar to the Layer Removal method, for the distortion prediction of machined components. This analytical modeling tool considers the initial geometry of the component, the residual stress profile of the bulk and the machining induced surface stresses. Furthermore, to validate the analytical model a comparison with finite element numerical model is presented, in terms of accuracy, computational time and usability. The results obtained reflect important benefits in favor of the analytical simulation model here presented, showing its potential as an industrial tool to use when dealing with machining distortions. Keywords: Machining Distortion, Analytical Modelling, FEM, Layer Removal, Aluminum, Titanium