Research on machining deformation of aluminum alloy rolled ring induced by residual stress

Xue, Nian-Pu; Yang, Ru; Wu, Qiong; Zhang, Zhang; Zhang, Yidu; Li, Lei; Guo, Jun

doi:10.1007/s00170-023-11068-y

Cited by 5 publications

(1 citation statement)

References 35 publications

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“…Therefore, key design considerations for certain structures include low thickness and high strength, with some parts having wall thicknesses as low as 1 mm to 2 mm [1]. These complex-shaped parts are typically crafted from rolled aluminum sheets and near-net extruded aluminum profiles but often require subsequent trimming [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Parameter Selection for Milling Machining of Thin-Walled Parts Based on Spatial Distribution of Side Blades

Tang,

Cai

2024

J. Phys.: Conf. Ser.

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In the machining of thin-walled components, the tool’s side edges play a pivotal role in the cutting process. This paper presents the establishment of the AdvantEdge 3D simulation model for the analysis of the contact conditions and the variation in cutting forces between the side edge and the machined surface across varying cutting depths. Subsequently, milling experiments were conducted to assess the impact of the side edge’s contact conditions on the surface quality of the machined parts, considering different cutting depths. The findings reveal that during side milling of thin-walled components, a lower number of teeth result in reduced cutting edges, decreased cutting forces, and improved surface quality. The selection of cutting depth should be made with due consideration to the contact conditions between the tool’s side edge and the workpiece. Ideally, the cutting depth should be less than the pitch of the side edge’s spatial curve to ensure that only a single cutting edge is engaged in the cutting process.

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Section: Introductionmentioning

confidence: 99%

Parameter Selection for Milling Machining of Thin-Walled Parts Based on Spatial Distribution of Side Blades

Tang,

Cai

2024

J. Phys.: Conf. Ser.

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Study of distortion on milled thin-wall aluminum parts influenced by initial residual stress and toolpath strategy

Zheng

Voyle

Tang

et al. 2023

Int J Adv Manuf Technol

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Monolithic aluminium alloy parts are highly required in aeronautical industry, but they show signi cant geometrical distortion after the machining process. This work investigated the distortion attributed by the initial residual stress of raw material and the machining induced residual stress during the milling process, as well as explored the effects of the machining toolpath strategy. Single-/multi-pocket parts were milled from 7050-T7451 aluminium blocks with different initial residual stress, and an element deletion method was developed for numerical study to simulate different sequences of material removal.It was revealed that the toolpath parallel to the long side of block caused more distortion on the side surfaces of nal part. The value of distortion was positively correlated to the magnitude of initial residual stress of raw material. The simulation results indicated that the distortion attributed by machining induced residual stress accounted for about 15% of nal distortion. The nding promotes the design optimization of machining monolithic parts by minimizing distortion, thereby bene tting the application of large monolithic parts in industry.

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Review of improvement of machinability and surface integrity in machining on aluminum alloys

Pimenov,

Kiran,

Khanna

et al. 2023

Int J Adv Manuf Technol

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Aluminum alloys are widely used in many industries, including aerospace, automotive, civil, and electrical engineering. When compared to pure aluminum, most aluminum alloys have lower electrical and thermal conductivity, corrosion resistance, and weldability, as well as a low density and specific gravity. At the same time, the properties of aluminum alloys vary significantly depending on the group, which has a significant impact on their machinability. This review article is focused on the study of machining characteristics of aluminum alloys, such as machinability, surface integrity, tool wear and tool life, material removal rate (MRR), and chip morphology. The directions of increasing machinability by controlling cutting parameters, cutting environment, such as dry machining, conventional cooling systems, minimum quantity of lubricant (MQL), cryogenic lubrication (CL), with tool geometry, and textured tools, are also considered; tool materials include coating, vibration, thermally, and hybrid assisted machining. The article discusses the main types of machining, namely, turning, milling, drilling, and grinding. It shows ways to increase the machinability of machining on aluminum alloys, as well as the advantages and disadvantages. From the literature, it can be concluded that tool wear when machining aluminum alloys is 30–40% lower than when machining steel alloys due to their higher ductility and lower strength. Surface integrity, affected by the cutting parameters and cutting temperatures — which can reach between 200 and 400 °C — can vary by up to 15% in hardness and 20% in surface roughness. Cutting tool characteristics can enhance surface finish by up to 25% and extend tool life, reducing edge formation by up to 30%. Chip morphology, influenced by factors such as cutting parameters and tool material, can improve tool life by up to 35%. Vibration techniques can reduce thermal effects and improve surface finish by up to 40%, reducing cutting forces by around 30%.

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Research on machining deformation of aluminum alloy rolled ring induced by residual stress

Cited by 5 publications

References 35 publications

Parameter Selection for Milling Machining of Thin-Walled Parts Based on Spatial Distribution of Side Blades

Parameter Selection for Milling Machining of Thin-Walled Parts Based on Spatial Distribution of Side Blades

Study of distortion on milled thin-wall aluminum parts influenced by initial residual stress and toolpath strategy

Review of improvement of machinability and surface integrity in machining on aluminum alloys

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