Machined Component Quality Improvements Through Manufacturing Process Simulation

Bowden, D. M.; Sova, B. J.; Beisiegel, A. L.; Halley, Jeremiah E.

doi:10.4271/2001-01-2607

Cited by 3 publications

(3 citation statements)

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“…A report in 2001 indicated that it cost Boeing company ≈290B USD to compensate for the distortion in machined components. [ 228 ] This underscores that residual stress distribution patterns should be accurately identified in the machining process. The research has shown that machined components with compressive residual stress would have a longer fatigue life than unmachined raw components.…”

Section: Origins and Effectsmentioning

confidence: 99%

Residual Stress in Engineering Materials: A Review

et al. 2021

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The accurate determination of residual stresses has a crucial role in understanding the complex interactions between microstructure, mechanical state, mode(s) of failure, and structural integrity. Moreover, the residual stress management concept contributes to industrial applications, aiming to improve the product's service performance and life cycle. In this regard, the industry requests rapid, efficient, and modern methods to identify and control the residual stress state. This review article contains three main sections. The first section covers different residual stress determination methods and reports the advancements over the recent decade. The second section includes the role of residual stresses in the performance of a broad range of materials including metallic alloys, polymers, ceramics, composites, and biomaterials. This is presented by classifying different science areas dealing with residual stresses into two main groups, including “origins” and “effects” of residual stresses. The range of topics covered are “welding, machining, curing/cooling, and spray coating processes,” “medical and dental sciences,” and “fatigue and fracture mechanisms.” The third section summarizes various strategies to effectively control residual stresses through different manufacturing procedures. It is hoped that the data provided herein serves as a valuable up‐to‐date reference for engineers and scientists in the field of residual stress.

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Section: Origins and Effectsmentioning

confidence: 99%

Residual Stress in Engineering Materials: A Review

et al. 2021

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“…By specialized thermal treatment of aerospace grade aluminum alloys they are strengthened so that various aerospace parts can be manufactured using thinner section resulting in weight reduction in aircraft construction with reduced fuel consumption and carbon footprint. Thermal treatment of aluminum alloys, however, results in residual stress generation which is a major contributor to part distortion during the manufacture of aerospace components [1]. Attempts to avoid or remedy distortions cost the aerospace industry tens of millions of Euros a year [2].…”

Section: Introductionmentioning

confidence: 99%

Development of accurate contour residual stress measurement technique for sustainable structural integrity assessment in additive manufacturing

Sayeed Hossain,

Harthy,

Naveed

et al. 2024

J. Phys.: Conf. Ser.

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Accurate analysis of residual stress present within an engineering component plays a fundamental role to its sustainable structural integrity assessment. This is particularly important for a safety critical component within the power generation sectors, aerospace, and oil and gas industries. The accurate stress analysis not only allows operators to determine the life remaining in a component but also avoid over-conservative estimates and thereby contribute to life extension of engineering plants and components. By utilizing and unifying multiple residual stress analysis tools of different nature a robust and more accurate method of stress analysis is achieved. The main aim of the current study focusses on the development and optimization of a robust residual stress tool based on the contour technique to accurately analyse inherent stress in an engineering component.

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“…It depends heavily on the experience of the operators, and repairing each structural part is very time-consuming. Some studies suggest that the impact of reshaping can be as high as 50% of the final cost of the component, thus compromising any manufacturing profitability [8]. Hence, there is a strong demand from the industry to derive operational assistance from numerical simulation tools [9].…”

Section: Introductionmentioning

confidence: 99%

Reshaping diagrams for bending straightening of forged aeronautical components

Mena

Aguado

Guinard

et al. 2020

Int J Adv Manuf Technol

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Large and thick-walled aluminium forgings exhibit shape distortions induced by residual stresses. To restore the nominal geometry, a series of highlymanual and time-consuming reshaping operations need to be carried out. In this paper, we are concerned with the development of efficient computer simulation tools to assist operators in bending straightening, which is one of the most common reshaping operations. Our approach is based on the computation of reshaping diagrams, a tool that allows selecting a nearly optimal bending load to be applied in order to minimize distortion. Most importantly, we show that the reshaping diagram needs not to account for the residual stress field, as its only effect is to shift of the reshaping di-This project has received funding from the European Union's Horizon 2020 research and innovation programme under the Marie Sk lodowska-Curie grant agreement No 675919.

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Machined Component Quality Improvements Through Manufacturing Process Simulation

Cited by 3 publications

References 0 publications

Residual Stress in Engineering Materials: A Review

Residual Stress in Engineering Materials: A Review

Development of accurate contour residual stress measurement technique for sustainable structural integrity assessment in additive manufacturing

Reshaping diagrams for bending straightening of forged aeronautical components

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