Skip to main content

Advertisement

SpringerLink
Log in

Experimental investigation of the application of parameter inversion for residual stress adjustment in five-axis milling using an annular cutter

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Five-axis milling makes it possible to control the relative pose between a tool and surface normal of a workpiece, and is widely used in manufacturing. In this study, an experimental investigation of the application of parameter inversion for residual stress adjustment in five-axis milling has been conducted based on two methods: an orthogonal experiment with interaction of factors and a random setting of the expected residual stress. The results of the orthogonal experiment with interactions of factors show that the significance of the influence of the machining parameters on the residual stress obtained with parameter inversion is similar to the experimental results. The results of the experiment with a random setting of the expected residual stress show that the average of the difference between the measured and expected results for the 30 cutting conditions is only 0.3951 MPa, which indicates that residual stress prediction using parameter inversion is statistically effective. Moreover, the results show that using parameter inversion, the correctness of the prediction of compressive and tensile residual stress is 73.33%, which is higher than the 50% value that is achievable without any adjustment. Overall, the results of the experimental investigation in this paper show that residual stress adjustment based on parameter inversion is applicable for five-axis milling, which shows the potential of this adjustment method for industrial applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5

Similar content being viewed by others

References

  1. Ghosh S, Rana VPS, Kain V, Mittal V, Baveja SK (2011) Role of residual stresses induced by industrial fabrication on stress corrosion cracking susceptibility of austenitic stainless steel. Mater Des 32(7):3823–3831. https://doi.org/10.1016/j.matdes.2011.03.012

    Article  Google Scholar 

  2. Lazoglu I, Ulutan D, Alaca BE, Engin S, Kaftanoglu B (2008) An enhanced analytical model for residual stress prediction in machining. CIRP Ann - Manuf Technol 57(1):81–84. https://doi.org/10.1016/j.cirp.2008.03.060

    Article  Google Scholar 

  3. Ulutan D, Lazoglu I, Dinc C (2009) Three-dimensional temperature predictions in machining processes using finite difference method. J Mater Process Technol 209(2):1111–1121. https://doi.org/10.1016/j.jmatprotec.2008.03.020

    Article  Google Scholar 

  4. M’Saoubi R, Chandrasekaran H (2011) Experimental study and modelling of tool temperature distribution in orthogonal cutting of AISI 316L and AISI 3115 steels. Int J Adv Manuf Technol 56(9-12):865–877. https://doi.org/10.1007/s00170-011-3257-y

    Article  Google Scholar 

  5. Huang K, Yang W, Chen Q, He S (2016) An experimental investigation of temperature distribution in workpiece machined surface layer in turning. Int J Adv Manuf Technol 85(5):1207–1215. https://doi.org/10.1007/s00170-015-8016-z

    Article  Google Scholar 

  6. Komanduri R, Hou ZB (2000) Thermal modeling of the metal cutting process: part I—temperature rise distribution due to shear plane heat source. Int J Mech Sci 42(9):1715–1752. https://doi.org/10.1016/S0020-7403(99)00070-3

    Article  MATH  Google Scholar 

  7. Huang K, Yang W (2016) Analytical model of temperature field in workpiece machined surface layer in orthogonal cutting. J Mater Process Technol 229:375–389. https://doi.org/10.1016/j.jmatprotec.2015.07.008

    Article  Google Scholar 

  8. Huang K, Yang W, Chen Q (2015) Analytical model of stress field in workpiece machined surface layer in orthogonal cutting. Int J Mech Sci 103:127–140. https://doi.org/10.1016/j.ijmecsci.2015.08.020

    Article  Google Scholar 

  9. Huang K, Yang W (2016) Analytical modeling of residual stress formation in workpiece material due to cutting. Int J Mech Sci 114:21–34. https://doi.org/10.1016/j.ijmecsci.2016.04.018

    Article  Google Scholar 

  10. Huang K, Yang W (2017) Analytical analysis of the mechanism of effects of machining parameter and tool parameter on residual stress based on multivariable decoupling method. Int J Mech Sci 128-129:659–679. https://doi.org/10.1016/j.ijmecsci.2017.05.031

    Article  Google Scholar 

  11. Chen W, Vanboven G, Rogge R (2007) The role of residual stress in neutral pH stress corrosion cracking of pipeline steels – part II: crack dormancy. Acta Mater 55(1):43–53. https://doi.org/10.1016/j.actamat.2006.07.021

    Article  Google Scholar 

  12. Withers PJ (2007) Residual stress and its role in failure. Rep Prog Phys 70(12):2211–2264. https://doi.org/10.1088/0034-4885/70/12/r04

    Article  Google Scholar 

  13. Arrazola PJ, Özel T, Umbrello D, Davies M, Jawahir IS (2013) Recent advances in modelling of metal machining processes. CIRP Ann - Manuf Technol 62(2):695–718. https://doi.org/10.1016/j.cirp.2013.05.006

    Article  Google Scholar 

  14. Brinksmeier E, Gläbe R, Klocke F, Lucca DA (2011) Process signatures – an alternative approach to predicting functional workpiece properties. Procedia Eng 19:44–52. https://doi.org/10.1016/j.proeng.2011.11.078

    Article  Google Scholar 

  15. Brinksmeier E, Klocke F, Lucca DA, Sölter J, Meyer D (2014) Process signatures – a new approach to solve the inverse surface integrity problem in machining processes. Procedia CIRP 13:429–434. https://doi.org/10.1016/j.procir.2014.04.073

    Article  Google Scholar 

  16. Huang K, Yang W, Ye X (2018) Adjustment of machining-induced residual stress based on parameter inversion. Int J Mech Sci 135:43–52. https://doi.org/10.1016/j.ijmecsci.2017.11.014

    Article  Google Scholar 

  17. Jin H, Yang W, Yan L (2012) Development of an improved energy-based method for residual stress assessment. Philos Mag 92(4):480–499. https://doi.org/10.1080/14786435.2011.616867

    Article  Google Scholar 

  18. He W, Xue W, Tang B (2017) Optimization test design method and data analysis. Chemical Industry Press, Beijing

    Google Scholar 

Download references

Acknowledgments

This work is supported by the Major State Basic Research Development Program of China (973 Program, Grant No. 2014CB046704). Special thanks to the Advanced Manufacturing and Technology Experiment Center (in the School of Mechanical Science and Engineering, Huazhong University of Science and Technology) and the Analysis and Testing Center of Huazhong University of Science and Technology for their help.

Author information

Authors and Affiliations

  1. Guangdong Bright Dream Robotics CO. LTD., Guangdong Province, Foshan, 528311, China

    Kun Huang

  2. State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Wenyu Yang & Yi Gao

  3. School of Energy and Power Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Xiaoming Ye

Authors
  1. Kun Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wenyu Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yi Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xiaoming Ye
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Kun Huang or Wenyu Yang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Appendix

Appendix

Table 8 Original residual stress measurement data for the cutting conditions in Table 2
Full size table
Table 9 Original residual stress measurement data for the cutting conditions in Table 5
Full size table
Table 10 Original residual stress measurement data for the cutting conditions in Table 7
Full size table

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Huang, K., Yang, W., Gao, Y. et al. Experimental investigation of the application of parameter inversion for residual stress adjustment in five-axis milling using an annular cutter. Int J Adv Manuf Technol 105, 3233–3247 (2019). https://doi.org/10.1007/s00170-019-04431-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04431-5

Keywords

Search

Navigation