Processing Parameters Optimization on Control of Residual Stresses and Distortion during High-Speed Milling of Thin-Walled Workpiece

Abstract

In the aerospace and auto industries, the residual tensile stresses will cause the structures broke and damaged. Hence, different methods were considered to optimize the machining processes. In this article, a residual stresses calculation model using AdvantEdge 2D turning was integrated with 2D milling physical model in order to analyze high-speed milling thin-walled workpiece. Through optimizing the processing parameters (improving the cutting speed and decreasing the cutting depth) during high-speed milling, not only we can get a high removal rate and receive a distribution of equably surface residual stresses, but also a slowing down trend of in-depth residual stress can be obtained. In addition, we evaluate this method using a typical part at the sensitive area, and the machining quality can be improved obviously.

Influence and optimization criterion of milling modes and process parameters on residual stress

“…Thiele J D [4] conducted experiments to explore the influence of tool rake Angle on the residual stress. Li BZ, Jing X H [5,6] set up a two-dimensional removal model to optimize spindle speed and cutting depth.…”