3D coupled thermo-mechanical simulation of surface roughness and residual stress in end milling aluminum alloy

Zhang, Yabo; Bai, Qingshun; Qing, Lingbo; Chen, Sheng-Min

doi:10.1007/s00170-022-10468-w

Cited by 2 publications

(1 citation statement)

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“…It was also confirmed that the cutting speed, depth of cut, as well as the feed per tooth had a significant impact on residual stress. Zhang et al [ 37 ] developed a 3D-coupled thermo-mechanical model for simulating model surface roughness and residual stress in the end milling of 5083 aluminum alloy. They used explicit dynamic analysis as an algorithm for the milling process, finding that the surface residual stress resulted from the compressed effect of the tool and that the tensile effect was a result of the thermal load, while the nature and value of residual stress varied depending on the employed technological parameters.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

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Section: Introductionmentioning

confidence: 99%