Effects of tool diameters on the residual stress and distortion induced by milling of thin-walled part

Jiang, Xin; Li, Beizhi; Yang, Jing; Zuo, Xiao Yan

doi:10.1007/s00170-012-4717-8

Cited by 42 publications

(17 citation statements)

References 29 publications

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“…Jiang et al investigated the effects of tool diameters on the residual stress in the milling process of a thin-walled part. They found that the distribution of residual stress was more uniform as the tool diameter increased [91]. For milling process of nickel alloy and titanium alloy, many research results indicated that increasing cutting speed will bring about the tensile residual stresses tend to become more compressive [92].…”

Section: Residual Stress Characteristic On Machined Surfacementioning

confidence: 99%

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

et al. 2018

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It has been proved that surface integrity alteration induced by machining process has a profound influence on the performance of a component. As a widely used processing technology, milling technology can process parts of different quality grades according to the processing conditions. The different cutting conditions will directly affect the surface state of the machined parts (surface texture, surface morphology, surface residual stress, etc.) and affect the final performance of the workpiece. Therefore, it is of great significance to reveal the mapping relationship between working conditions, surface integrity, and parts performance in milling process for the rational selection of cutting conditions. The effects of cutting parameters such as cutting speed, feed speed, cutting depth, and tool wear on the machined surface integrity during milling are emphatically reviewed. At the same time, the relationship between the machined surface integrity and the performance of parts is also revealed. Furthermore, problems that exist in the study of surface integrity and workpiece performance in milling process are pointed out and we also suggest that more research should be conducted in this area in future.

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Section: Residual Stress Characteristic On Machined Surfacementioning

confidence: 99%

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

et al. 2018

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“…Experiments of Nasr et al [3] show that the rounded corner of the blade would increase the residual tensile stress of the workpiece surface. Jiang et al [4] found that with the increase of cutter diameter, residual stress and deformation can be reduced and material removal rate can be improved.…”

Section: Introductionmentioning

confidence: 99%

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

Kong

Zhou

Xu³

et al. 2019

EPJ Web Conf.

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With the increasing application of curved thin-walled parts, the evaluation and control of curved surface residual stress in milling are becoming increasingly demanding. However, effects of milling parameters on distribution of residual stress remains a major challenge in the present aerospace research areas. In this paper, , impacts of milling parameters on curved surface residual stress have been investigated in a series of residual stress experiments and simulations. It is found that the residual stress can be lowered by increasing milling speed and tool radius within a reasonable range. The superposition of curved surface residual stress under two machining conditions have been analyzed using the milling simulation model. It has been found that the curved surface residual stress induced by the subsequent cutting will be superimposed on the curved surface residual stress induced by the previous cutting and that the superposition rates of residual stress induced by up milling are larger than down milling.

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“…The results showed that the residual stress increased as the number of switching cycles increased. Based on the uncut chip thickness (UCT) model, Jiang et al [26,27] found that residual tangential stress is influenced by the UCT and it is possible to optimize the residual stress distribution by controlling UCT (feed rate and tool diameter) with high-speed milling, and in order to control the material removal rate, they proposed a method by optimizing the milling tool diameters based on the relation between residual stress and UCT. Zhang et al [28] provided some insight into the uniformity of compressive residual stress generated by massive overlapping laser shock peening impacts, which has a lot of practical use in engineering application.…”

Section: Introductionmentioning

confidence: 99%

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

Zhang

2016

Metals

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Abstract:The deformation of aeronautical monolithic components due to CNC machining is a bottle-neck issue in the aviation industry. The residual stress releases and redistributes in the process of material removal, and the distortion of the monolithic component is generated. The traditional one-side machining method will produce oversize deformation. Based on the three-stage CNC machining method, the quasi-symmetric machining method is developed in this study to reduce deformation by symmetry material removal using the M-symmetry distribution law of residual stress. The mechanism of milling deformation due to residual stress is investigated. A deformation experiment was conducted using traditional one-side machining method and quasi-symmetric machining method to compare with finite element method (FEM). The deformation parameters are validated by comparative results. Most of the errors are within 10%. The reason for these errors is determined to improve the reliability of the method. Moreover, the maximum deformation value of using quasi-symmetric machining method is within 20% of that of using the traditional one-side machining method. This result shows the quasi-symmetric machining method is effective in reducing deformation caused by residual stress. Thus, this research introduces an effective method for reducing the deformation of monolithic thin-walled components in the CNC milling process.

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Effects of tool diameters on the residual stress and distortion induced by milling of thin-walled part

Cited by 42 publications

References 29 publications

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

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