An analytical model for predicting the machining deformation of a plate blank considers biaxial initial residual stresses

The simulation of a complete manufacturing process to produce an aero engine case, including forging, rolling, and machining processes, is analyzed via finite element software. The deformation of the turning and drilling processes is quantitatively studied using the energy principles. Firstly, simulations of multi-stage forging of aero engine case and machining-induced residual stress are conducted and verified via the residual stresses test in order to provide the initial elastic strain energy condition prior to machining processes. The effects of blank forging-induced residual stress and machining-induced residual stress on the deformation of titanium alloys aero engine case are investigated. Secondly, a potential energy expression for the machining processes is developed. The predicted results of turning and drilling simulations indicate that there is an optimal process in which the deformation and potential energy decline rapidly compared with the other processes and finally, gradually stabilize at the end of the process.

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“…During the machining process, the equilibrium was broken by material removal. The workpiece was distorted to another static balance [26,27].…”

Section: Fe Model and Boundary Conditionsmentioning

confidence: 99%

Machining Distortion of Titanium Alloys Aero Engine Case Based on the Energy Principles

Wang

Sun

Chen

et al. 2018

Metals

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“…In this regard, a work based on an analytical model predicted frame part deformation in 1D considering MIRS and BIRS, in which BIRS were determined using the slope method [25]. Following a similar formulation, an analytical model developed for machining deformation prediction established quantitative relationships between deformation and biaxial BIRS under three typical machining strategies, as Gao et al reported [26]. Both analytical models were verified by FE simulations and experimental test.…”

Section: Introductionmentioning

confidence: 97%

Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal

Aurrekoetxea

Lacalle²,

Llanos

2020

Materials

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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.

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“…In the industry, problems related to large-sized thin-walled elements and their significant deformations occurring directly after removing the clamping forces are quite common. It is assumed that the reasons for the occurring deformations can be as follows [ 19 , 20 , 21 ]: post-machining residual stresses introduced during machining; residual stresses introduced during semi-finished product manufacturing (i.e., technological history effect); residual stresses introduced during heat treatment. …”

Section: Introductionmentioning

confidence: 99%

“…Thus, the end condition of residual stresses in the surface layer, after machining, is important [ 19 , 21 ].…”

Section: Introductionmentioning

confidence: 99%

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

et al. 2020

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The paper examines the impact of selected machining techniques and the semi-finished product technological history on deformations of thin-walled elements made of EN AW-2024 T351 aluminium alloy after milling. The following techniques have been implemented: High Performance Cutting, High Speed Cutting, conventional finishing (CF) and combinations of these techniques. As for the semi-finished product technological history, the rolling direction has been analysed. It has been assumed that it can be relevant in relation to the cutting tool feed direction and, in consequence, exert considerable impact on the stress, as well as deformation following machining. The interest in this issue proceeds from significant challenges faced by the industry, particularly in the aerospace sector. The analysis of results obtained has shown that milling in the direction perpendicular to the rolling direction results in larger deformations than milling in the parallel direction. Additionally, it has been revealed that applying a correctly selected machining technique makes it possible to minimise post-machining deformations of thin-walled elements.

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An analytical model for predicting the machining deformation of a plate blank considers biaxial initial residual stresses

Cited by 52 publications

References 61 publications

Machining Distortion of Titanium Alloys Aero Engine Case Based on the Energy Principles

Machining Distortion of Titanium Alloys Aero Engine Case Based on the Energy Principles

Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

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