Tool overlap effect on redistributed residual stress and shape distortion produced by the machining of thin-walled aluminum parts

  • Xiaohui Jiang
  • Zhenya Zhang
  • Zishan Ding
  • Omar Fergani
  • Steven Y. Liang


As the main factor, residual stress undoubtedly restricts the long-term stability of high-precision machining quality parts, arresting an extensive attention on studying its control method. Therefore, a model is meticulously proposed, along with the optimization method of the overlap rate of cutting tool path. In the roughing, the selection of a larger magnitude of overlap coefficient K is found to be necessary for the optimization of the surface machined residual stress, followed by an indispensable selection of smaller K values in the finishing. The shrinking overlap coefficient K echoes with the decreasing influence of the deformation affected by the residual stress distribution, inevitably accompanied by the lowering material removal rate. Based on all the optimization results, an aerospace thin-walled part is adopted in the application case to verify the proposed approach.


Tool overlap Residual stress Distortion Milling Thin-walled parts 


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Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  • Xiaohui Jiang
    • 1
  • Zhenya Zhang
    • 1
  • Zishan Ding
    • 1
  • Omar Fergani
    • 2
  • Steven Y. Liang
    • 3
  1. 1.College of Mechanical EngineeringUniversity of Shanghai for Science & TechnologyShanghaiPeople’s Republic of China
  2. 2.NTNU-Department of Engineering Design and MaterialNorwegian University of Science and TechnologyTrondheimNorway
  3. 3.The George W. Woodruff School of Mechanical EngineeringGeorgia Institute of TechnologyAtlantaUSA

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