Uncertainty Assessment for Bulk Residual Stress Characterization Using Layer Removal Method

Aurrekoetxea, Maria; Lacalle, Luis Norberto López de; Zelaieta, Oier; Llanos, Iñigo

doi:10.1007/s11340-022-00918-7

Cited by 4 publications

(1 citation statement)

References 21 publications

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“…The measurement of residual stresses on large pieces is a delicate problem. Some difficulties come from measurement errors as noted by Aurrekoetxa et al [12] and others from the fact that this procedure is destructive (holes methods and slice-by-slice procedure). The case of thin-walled pieces or large pieces susceptible to distortion is even more critical because of several factors that influence the distortion [13].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

et al. 2023

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The residual stresses state that a mechanical part obtained after machining is a crucial factor that impacts its in-service performance. This stress state is influenced by the thermomechanical loads exerted on the parts during the machining process, which are, in turn, determined by the tool parameters, process, and machining conditions. The aim of the present research was to anticipate how the cutting tool’s edge radius, rake angle, and clearance angle would affect the forces, temperature, and residual stresses induced while orthogonally cutting aluminum AA6061-T6. To achieve this, two-dimensional DEFORM™ software was utilized to develop a finite element model. The residual stresses trend results obtained demonstrated that rake angles of 0° and 17.5–20° values with a small edge radius (5 to 10 µm) and clearance angles of 7 and 17.5° values gave higher compressive stresses. The obtained simulated results were in good agreement with the experiments. The cutting forces, the temperature, and the maximum and minimum machining-induced residual stresses were found to be influenced more by the tool edge radius and the tool rake angle. The influence of the clearance angles on the above-mentioned machining responses was the least. Residual stresses can have a significant impact on the in-service performance of machined parts. The obtained results will help engineers select or design tools that promote a desired surface integrity during machining. This task is not obvious in practice because of difficulties in measuring residual stresses and also because the machining parameters and the tool geometry parameters have different and opposite impacts on thermo-mechanical loads, productivity, and on machining induced residual stresses.

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Section: Introductionmentioning

confidence: 99%

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

et al. 2023

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

Xue

Yang²,

Wu³

et al. 2023

Int J Adv Manuf Technol

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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.

show abstract

Uncertainty Assessment for Bulk Residual Stress Characterization Using Layer Removal Method

Cited by 4 publications

References 21 publications

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

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

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

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