Methodology for aluminium part machining quality improvement considering mechanical properties and process conditions

Cerutti, Xavier; Mocellin, Katia; Hassini, Sami; Blaysat, Benoît; Duc, Emmanuel

doi:10.1016/j.cirpj.2016.07.004

Cited by 33 publications

(14 citation statements)

References 36 publications

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“…Theoretically, if the residual stress in a forged part is known before the machining step, it would be possible to determine the best location for the final geometry inside the blank, which minimizes any possible distortion. This approach works well for parts made from rolled plates [4,6] due to the residual stress field is easier to determine compared to forged parts [25]. For the latter, important deviations from the numerical prediction respect to the real distortion where reported by Cerutti [5], as shown in Figure 7.…”

Section: Reshaping Simulation: Challenges and Perspectivesmentioning

confidence: 93%

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Mena

Guinard

Aguado

et al. 2020

Computational Methods in Applied Sciences

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Distortions after machining of large aluminum forgings are a recurrent problem for the aeronautical industry. These deviations from design geometry are caused by the presence of residual stresses, which are developed along the manufacturing chain. To solve this problem, a series of post-machining operations called reshaping are required. Despite reshaping manages to restore the correct geometry, it is highly manual and time-consuming, therefore, there is a need at an industrial level to use numerical simulation to study reshaping. The present document describes the problem of distortion, the operations required to mitigate these geometrical defects and the challenges associated to simulate reshaping.

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Section: Reshaping Simulation: Challenges and Perspectivesmentioning

confidence: 93%

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Mena

Guinard

Aguado

et al. 2020

Computational Methods in Applied Sciences

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show abstract

“…This hypothesis is based on a very low plastic strain and negligible thermal effect due to milling when the tool rotation speed and feed are high. Yang et al [18] and Cerutti et al [9] also assumed that the main factor affecting part distortion is the initial residual stresses (before machining) and that those induced during milling are of second order. To validate these hypotheses, a comparison was conducted between part distortion before and after removing layers by wire electrical discharge machining (EDM) [19].…”

Section: Principle Of Layer Removal Methodsmentioning

confidence: 99%

“…A few of the benefits of this new clamping system are the prevention of any movement and the ensured stability of the sample during machining, which is possible when a fixture clamp with parallel jaws is used, as shown by Richter-Trummer et al [8]. Furthermore, Cerutti et al [9] considered that the fixture elements have to be located in the most rigid areas of the workpiece to avoid reflections during clamping.…”

Section: Introductionmentioning

confidence: 99%

Instrumented clamping device and numerical simulations to study machining distortion

Cherif

Cotton

Poulachon

et al. 2019

Int J Adv Manuf Technol

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Machining part distortion is due to residual stresses induced by previous manufacturing processes. This study aims to evaluate the influence of machining conditions on AISI 316L plate distortion. Therefore, a special experimental device with force sensors integrated in the clamping system and numerical model of distortion were developed. Residual stresses due to previous machining processes were measured using a layer removal method and neutron diffraction technique. Then, distributions of these residual stresses were integrated in a developed model of machining distortion, which considers the clamping and machining sequence effects after each stage of the toolpath. A comparison of the experimental and numerical results revealed that the finite element method can adequately predict machining distortion. The results also suggest that clamping and machining sequence can affect part distortion.

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“…It is related to the accumulation of residual stresses resulting from the semi-finished product technological history. During machining, the balance of the underlying stress condition is disrupted and new stresses are introduced, which results in the occurrence of undesirable deformations [ 19 , 21 , 32 , 33 , 34 , 35 , 36 ].…”

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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Methodology for aluminium part machining quality improvement considering mechanical properties and process conditions

Cited by 33 publications

References 36 publications

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Instrumented clamping device and numerical simulations to study machining distortion

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

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