Simulation based compensation techniques to minimize distortion of thin-walled monolithic aluminum parts due to residual stresses

Weber, Daniel; Kirsch, Benjamin; Jonsson, Julianne E.; D’Elia, Christopher R.; Linke, Barbara; Hill, Michael R.; Aurich, Jan C.

doi:10.1016/j.cirpj.2022.05.016

Cited by 15 publications

(5 citation statements)

References 39 publications

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“…The transition structure and final part have acceptable maximum relative errors of 24.6 % and 23.1 %, respectively, between theoretical calculation results and experimental results. Error generation is primarily caused by three factors (Ye et al, 2020;Weber et al, 2022;Huang et al, 2022): (1) the residual stress brought on by machining is not considered; (2) the effects of clamping and cutting load on machining distortion are not considered;…”

Section: Machining Testmentioning

confidence: 99%

“…It is possible to significantly lessen the distortion for the two components of milling by adjusting the processing conditions and using a 48 % suspension of maize starch. The impact of both types -the milling path method and the wall thickness on the distortion -was originally investigated by Weber et al (2022). Then, the process parameters, the part topology and the process strategy were determined to be the three primary categories for pre-control distortion techniques.…”

Section: Introductionmentioning

confidence: 99%

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Machining distortion control of long beam parts based on optimal design of transition structure

Fan,

Han,

Zhang

2023

Mech. Sci.

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Abstract. In the machining of monolithic components, machining distortion is a severe issue. The presence of initial residual stress is a major contributor to machining distortion. This paper proposes an approach to control the machining distortion of long beam parts by optimizing the workpiece structure before the start of the finishing stage, i.e. the transition structure. The first step is to establish a machining distortion analytical model for long beam parts with an identical cross-section, which is based on reasonable assumptions such as material linear elasticity and ignoring the influence of cutting heat. Then, an optimization model for the cross-section of the transition structure is developed, with the objective function defined as the minimum difference between the predicted distortion of the final part and the transition structure. Finally, a U-shaped beam is designed, followed by numerical simulation and machining experiments for verification. The theoretical maximum distortion of the optimized transition structure and the final part are −0.174 and −0.1782 mm, respectively, with a relative error of 2.9 %. The results of machining experiments and finite-element simulation demonstrate the effectiveness of the proposed model.

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Section: Machining Testmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Machining distortion control of long beam parts based on optimal design of transition structure

Fan,

Han,

Zhang

2023

Mech. Sci.

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“…Studies [ 30 , 31 , 32 , 33 ] demonstrated that the strain in the thin-walled part resulted not only from thermo-mechanical load impact and vibration but also from residual stress, which could be put under two groups. The first included machining-induced residual stress, while the other included residual stress induced by operations such as rolling or thermal treatment.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

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“…Weber et al, considering the combined effects of initial and machining-induced residual stresses, advocated for a 3D linear elasticity finite element model. Applying this to frame-like structural components, they critically analyzed the impact of milling paths and wall thickness on the deformation of frame-like aluminium alloy thin-walled structures [25].…”

Section: Introductionmentioning

confidence: 99%

Semi-Analytical Solution Model for Bending Deformation of T-Shaped Aviation Aluminium Alloy Components under Residual Stress

Li,

Yi,

Tian

et al. 2024

Metals

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Structures composed of aviation aluminium alloys, characterized by their limited rigidity and thin-walled configurations, frequently exhibit deformation after processing. This paper presents an investigation into T-shaped components fabricated from pre-stretched 7075-T7451 aviation aluminium alloy sheets, examining the effects of residual stress and the geometrical parameters of T-shaped components on their deformational behavior. A semi-analytical model, developed to elucidate the bending deformation of T-shaped components subjected to residual stress, was validated through finite element analysis and empirical cutting experiments. The experimental results revealed that the bending deformation deflection of the T-shaped specimen was 0.920 mm, deviating by a mere 0.011 mm from the prediction provided by the semi-analytical model, resulting in an inconsequential error margin of 1.2%. This concordance underscores the precision and accuracy of the semi-analytical model specifically designed for T-shaped components. Moreover, the model’s simplicity and ease of application make it an effective tool for predicting the bending deformation of thin-walled T-shaped components under a range of residual stresses and dimensional variations, thereby demonstrating its significant utility in engineering applications.

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Simulation based compensation techniques to minimize distortion of thin-walled monolithic aluminum parts due to residual stresses

Cited by 15 publications

References 39 publications

Machining distortion control of long beam parts based on optimal design of transition structure

Machining distortion control of long beam parts based on optimal design of transition structure

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Semi-Analytical Solution Model for Bending Deformation of T-Shaped Aviation Aluminium Alloy Components under Residual Stress

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