Skip to main content
SpringerLink
Log in

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

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

Abstract

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

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
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

References

  1. Wang B et al (2021) Advancements in material removal mechanism and surface integrity of high speed metal cutting: a review. Int J Mach Tools Manuf 166:103744. https://doi.org/10.1016/j.ijmachtools.2021.103744

    Article  Google Scholar 

  2. Ranjan Soren T, Kumar R, Panigrahi I, Kumar Sahoo A, Panda A, Kumar Das R (2019) Machinability behavior of aluminium alloys: a brief study. Mater Today Proc 18:5069–5075. https://doi.org/10.1016/j.matpr.2019.07.502

    Article  Google Scholar 

  3. Santos MC, Machado AR, Sales WF, Barrozo MAS, Ezugwu EO (2016) Machining of aluminum alloys: a review. Int J Adv Manuf Technol 86(9):3067–3080. https://doi.org/10.1007/s00170-016-8431-9

    Article  Google Scholar 

  4. Zhou B, Liu B, Zhang S (2021) The advancement of 7XXX series aluminum alloys for aircraft structures: a review. Metals 11:5–5. https://doi.org/10.3390/met11050718

    Article  Google Scholar 

  5. Li J, Wang S (2017) Distortion caused by residual stresses in machining aeronautical aluminum alloy parts: recent advances. Int J Adv Manuf Technol 89(1):997–1012. https://doi.org/10.1007/s00170-016-9066-6

    Article  Google Scholar 

  6. Sim WM (2011) Residual stress engineering in manufacture of aerospace structural parts. In: 3rd International conference on distorsions engineering, pp 187–194

  7. Aurrekoetxea M, Llanos I, Zelaieta O, López de Lacalle LN (2022) Towards advanced prediction and control of machining distortion: a comprehensive review. Int J Adv Manuf Technol 122(7):2823–2848. https://doi.org/10.1007/s00170-022-10087-5

    Article  Google Scholar 

  8. Withers PJ, Bhadeshia HKDH (2001) Residual stress. Part 1 – Measurement techniques. Mater Sci Technol 17(4):355–365. https://doi.org/10.1179/026708301101509980

    Article  Google Scholar 

  9. Withers PJ, Bhadeshia HKDH (2001) Residual stress. Part 2 – Nature and origins. Mater Sci Technol 17(4):366–375. https://doi.org/10.1179/026708301101510087

    Article  Google Scholar 

  10. Guo J, Fu H, Pan B, Kang R (2021) Recent progress of residual stress measurement methods: a review. Chin J Aeronaut 34(2):54–78. https://doi.org/10.1016/j.cja.2019.10.010

    Article  Google Scholar 

  11. Prime MB (2000) Cross-sectional mapping of residual stresses by measuring the surface contour after a cut. J Eng Mater Technol 123(2):162–168. https://doi.org/10.1115/1.1345526

    Article  Google Scholar 

  12. Bueckner HF (2022) The propagation of cracks and the energy of elastic deformation. Trans Am Soc Mech Eng 80(6):1225–1229. https://doi.org/10.1115/1.4012657

    Article  Google Scholar 

  13. Chighizola CR et al (2021) Intermethod comparison and evaluation of measured near surface residual stress in milled aluminum. Exp Mech 61(8):1309–1322. https://doi.org/10.1007/s11340-021-00734-5

    Article  Google Scholar 

  14. Tabatabaeian A, Ghasemi AR, Shokrieh MM, Marzbanrad B, Baraheni M, Fotouhi M (2022) Residual stress in engineering materials: a review. Adv Eng Mater 24(3):2100786. https://doi.org/10.1002/adem.202100786

    Article  Google Scholar 

  15. Rai JK, Xirouchakis P (2008) Finite element method based machining simulation environment for analyzing part errors induced during milling of thin-walled components. Int J Mach Tools Manuf 48(6):629–643. https://doi.org/10.1016/j.ijmachtools.2007.11.004

    Article  Google Scholar 

  16. Chighizola CR et al (2022) The effect of bulk residual stress on milling-induced residual stress and distortion. Exp Mech. https://doi.org/10.1007/s11340-022-00843-9

    Article  Google Scholar 

  17. Huang X, Sun J, Li J (2015) Effect of initial residual stress and machining-induced residual stress on the deformation of aluminium alloy plate. Stroj Vestn J Mech Eng 61(2):131–137. https://doi.org/10.5545/sv-jme.2014.1897

    Article  Google Scholar 

  18. Wan M, Ye X-Y, Yang Y, Zhang W-H (2017) Theoretical prediction of machining-induced residual stresses in three-dimensional oblique milling processes. Int J Mech Sci 133:426–437. https://doi.org/10.1016/j.ijmecsci.2017.09.005

    Article  Google Scholar 

  19. Madariaga A, Perez I, Arrazola PJ, Sanchez R, Ruiz JJ, Rubio FJ (2018) Reduction of distortions in large aluminium parts by controlling machining-induced residual stresses. Int J Adv Manuf Technol 97(1):967–978. https://doi.org/10.1007/s00170-018-1965-2

    Article  Google Scholar 

  20. Mathews R, Sunny S, Malik A, Halley J (2022) Coupling between inherent and machining-induced residual stresses in aluminum components. Int J Mech Sci 213:106865. https://doi.org/10.1016/j.ijmecsci.2021.106865

    Article  Google Scholar 

  21. Yang Y, Li M, Li KR (2014) Comparison and analysis of main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component. Int J Adv Manuf Technol 70(9):1803–1811. https://doi.org/10.1007/s00170-013-5431-x

    Article  Google Scholar 

  22. Weber D et al (2021) Analysis of machining-induced residual stresses of milled aluminum workpieces, their repeatability, and their resulting distortion. Int J Adv Manuf Technol 115(4):1089–1110. https://doi.org/10.1007/s00170-021-07171-7

    Article  Google Scholar 

  23. Wan M, Ye X-Y, Wen D-Y, Zhang WH (2019) Modeling of machining-induced residual stresses. J Mater Sci 54(1):1–35. https://doi.org/10.1007/s10853-018-2808-0

    Article  Google Scholar 

  24. Zhao Z, Li Y, Liu C, Liu X (2021) Predicting part deformation based on deformation force data using physics-informed latent variable model. Robot Comput-Integr Manuf 72:102204. https://doi.org/10.1016/j.rcim.2021.102204

    Article  Google Scholar 

  25. Cerutti X, Mocellin K (2016) Influence of the machining sequence on the residual stress redistribution and machining quality: analysis and improvement using numerical simulations. Int J Adv Manuf Technol 83(1):489–503. https://doi.org/10.1007/s00170-015-7521-4

    Article  Google Scholar 

  26. Chabeauti H, Ritou M, Lavisse B, Germain G, Charbonnier V (2022) Numerical investigation and modeling of residual stress field variability impacting the machining deformations of forged part. Procedia CIRP 108:687–692. https://doi.org/10.1016/j.procir.2022.04.079

    Article  Google Scholar 

  27. Hao X, Li Y, Chen G, Liu C (2018) 6+X locating principle based on dynamic mass centers of structural parts machined by responsive fixtures. Int J Mach Tools Manuf 125:112–122. https://doi.org/10.1016/j.ijmachtools.2017.11.006

    Article  Google Scholar 

  28. Chen Z, Yue C, Xu Y, Liu X, Liang SY (2023) An analytical machining deformation model of H-section multi-frame beam integral components. J Mater Process Technol 314:117907. https://doi.org/10.1016/j.jmatprotec.2023.117907

    Article  Google Scholar 

  29. Xue N-P et al (2023) Research on machining deformation of aluminum alloy rolled ring induced by residual stress. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-023-11068-y

    Article  Google Scholar 

  30. Aurrekoetxea M, López de Lacalle LN, Zelaieta O, Llanos I (2023) Uncertainty assessment for bulk residual stress characterization using layer removal method. Exp Mech 63(2):323–335. https://doi.org/10.1007/s11340-022-00918-7

    Article  Google Scholar 

  31. Zhu P, Liu Z, Ren X, Cai Y (2022) Machining distortion for thin-walled superalloy GH4169 caused by residual stress and manufacturing sequences. Metals 12(9):9. https://doi.org/10.3390/met12091460

    Article  Google Scholar 

  32. Wang SQ, He CL, Cao ZM (2021) Machining distortion in the milling of multi-frame components. J Manuf Process 68:1158–1175. https://doi.org/10.1016/j.jmapro.2021.06.024

    Article  Google Scholar 

  33. Sun H, Peng F, Zhao S, Zhou L, Yan R, Huang H (2022) Uncertainty calibration and quantification of surrogate model for estimating the machining distortion of thin-walled parts. Int J Adv Manuf Technol 120(1):719–741. https://doi.org/10.1007/s00170-021-08371-x

    Article  Google Scholar 

  34. Li Y et al (2023) Influence of material removal strategy on machining deformation of aluminum plates with asymmetric residual stresses. Materials 16(5):5. https://doi.org/10.3390/ma16052033

    Article  Google Scholar 

  35. Wang B, Liu Z, Song Q, Wan Y, Shi Z (2016) Proper selection of cutting parameters and cutting tool angle to lower the specific cutting energy during high speed machining of 7050–T7451 aluminum alloy. J Clean Prod 129:292–304. https://doi.org/10.1016/j.jclepro.2016.04.071

    Article  Google Scholar 

  36. Huang X, Sun J, Li J (2015) Finite element simulation and experimental investigation on the residual stress-related monolithic component deformation. Int J Adv Manuf Technol 77(5):1035–1041. https://doi.org/10.1007/s00170-014-6533-9

    Article  Google Scholar 

Download references

Funding

This work was supported by project PRP/011/20FX from the Hong Kong SAR Government Innovation and Technology Commission (ITC).

Author information

Authors and Affiliations

  1. The Aviation Services Research Centre, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong

    Jun-Yuan Zheng, Robert Voyle, Hon Ping Tang & Anthony Mannion

Authors
  1. Jun-Yuan Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Robert Voyle
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hon Ping Tang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Anthony Mannion
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jun-Yuan Zheng: conceptualization, methodology, investigation, validation, visualization, writing — original draft, and writing — review and editing.

Robert Voyle: conceptualization, methodology, experiment, and supervision

Hon Ping Tang: software, investigation, and validation

Anthony Mannion: experiment and investigation

Corresponding author

Correspondence to Jun-Yuan Zheng.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

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

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zheng, JY., Voyle, R., Tang, H.P. et al. Study of distortion on milled thin-wall aluminum parts influenced by initial residual stress and toolpath strategy. Int J Adv Manuf Technol 127, 237–251 (2023). https://doi.org/10.1007/s00170-023-11519-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11519-6

Keywords

Search

Navigation