Prediction of distortion induced by machining residual stresses in thin-walled components ORIGINAL ARTICLE First Online: 05 January 2018 Received: 23 May 2017 Accepted: 09 November 2017 Abstract
Machining of thin-walled components is standard practice in many fields such as spaceflight, aviation, automobile, medical equipment manufacturing, etc. When these thin-walled components are machined, however, part distortions arise from machining-induced stresses resulting from high cutting forces and temperatures. In this paper, a method of predicting distortion induced by machining residual stresses in thin-walled components is proposed, which includes an empirical model for predicting machining residual stresses with different cutting parameters and a modified FEM model for predicting the resulted distortion. On the basis of the measured residual stress results, an exponentially decaying sine function is fitted using the particle swarm optimization method and the coefficients of the fitting function are regressed with cutting parameters. General FEM software ABAQUS is used to create and mesh the thin-walled component. Standard parts of the same material with the experimental samples are machined to make modification to the predicted residual stress profiles under the arranged cutting conditions. The modified residual stress distributions are applied into ABAQUS to calculate the distortion of the experimental samples. Two experimental samples are machined to validate the prediction methodology. The results demonstrate that the proposed method can significantly improve the distortion prediction accuracy.
Keywords Distortion Residual stresses Empirical model Modification Thin-walled components Notes Acknowledgements
This study was supported by the National Natural Science Foundation, China (No. 51475382).
Bowden DM, Halley JE (2000) Aluminum reliability improvement program-final report. The Boeing Company, Chicago
Ma Y, Feng P, Zhang J, Wu Z, Yu D (2016) Prediction of surface residual stress after end milling based on cutting force and temperature. J Mater Process Technol 235:41–48.
https://doi.org/10.1016/j.jmatprotec.2016.04.002 CrossRef Google Scholar
Sadat AB, Reddy MY (1992) Surface integrity of Inconel 718 nickel base superalloy using controlled and natural contact length tools, Part 1. Lubricated, Exp Mech 282–288
Sadat AB, Reddy MY (1993) Surface integrity of Inconel 718 nickel base superalloy using controlled and natural contact length tools, Part 2. Unlubricated, Exp. Mech 343–348
Schlauer C, Peng RL, Oden M (2002) Residual stresses in a nickel-based superalloy introduced by turning. Mater Sci Forums 404-407:173–178.
https://doi.org/10.4028/www.scientific.net/MSF.404-407.173 CrossRef Google Scholar
Outeiro JC, Dias AM, Jawahir IS (2006) On the effects of residual stresses induced by coated and uncoated cutting tools with finite edge radii in turning operations. CIRP Ann Manuf Technol 55(1):111–116.
https://doi.org/10.1016/S0007-8506(07)60378-3 CrossRef Google Scholar
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(5-8):1035–1041.
https://doi.org/10.1007/s00170-014-6533-9 CrossRef Google Scholar
Yang Y, Li M, Li K (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(9-12):1803–1811.
https://doi.org/10.1007/s00170-013-5431-x CrossRef Google Scholar
Young KA (2005) Machining-induced residual stress and distortion of thin parts. PhD, Washington University, USA
Marusich TD, Usui S, Terauds KJ (2008) Finite element modelling of part distortion. In: proceedings of the 2nd international conference in distortion Engineering 133–142
Zhang Z, Li L, Yang Y, He N, Zhao W (2014) Machining distortion minimization for the manufacturing of aeronautical structure. Int J Adv Manuf Technol 73(9-12):1765–1773.
https://doi.org/10.1007/s00170-014-5994-1 CrossRef Google Scholar
Brinksmeier E, Solter J (2009) Prediction of shape deviations in machining. CIRP Annal 58(1):507–510.
https://doi.org/10.1016/j.cirp.2009.03.123 CrossRef Google Scholar
Cerutti X, Arsene S, Mocellin K (2016) Prediction of machining quality due to the initial residual stress redistribution of aerospace structural parts made of low-density aluminium alloy rolled plates. Int J Mater Form 9(5):677–690.
https://doi.org/10.1007/s12289-015-1254-7 CrossRef Google Scholar
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(1-4):489–503.
https://doi.org/10.1007/s00170-015-7521-4 CrossRef Google Scholar
Fergani O, Lazoglu I, Mkaddem A, Mansori ME, Liang SY (2014) Analytical modeling of residual stress and the induced deflection of a milled thin plate. Int J Adv Manuf Technol 75(1-4):455–463.
https://doi.org/10.1007/s00170-014-6146-3 CrossRef Google Scholar
Masoudi S, Amini S, Saeidi E, Eslami-Chalander H (2015) Effect of machining-induced residual stress on the distortion of thin-walled parts. Int J Adv Manuf Technol 76(1-4):597–608.
https://doi.org/10.1007/s00170-014-6281-x CrossRef Google Scholar
Wang J, Zhang D, Wu B, Luo M (2017) Numerical and empirical modelling of machining-induced residual stresses in ball end milling of Inconel 718. Procedia CIRP 58:7–12.
https://doi.org/10.1016/j.procir.2017.03.177 CrossRef Google Scholar
Ulutan D, Arisoy YM, Özel T, Mears L (2014) Empirical modeling of residual stress profile in machining nickel based superalloys using the exponentially decaying cosine function. Procedia CIRP 13:365–370.
https://doi.org/10.1016/j.procir.2014.04.062 CrossRef Google Scholar
Yang D, Liu Z, Ren X, Zhuang P (2016) Hybrid modeling with finite element and statistical methods for residual stress prediction in peripheral milling of titanium alloy. Int J Mech Sci 108-109:29–38.
https://doi.org/10.1016/j.ijmecsci.2016.01.027 CrossRef Google Scholar
Wang J, Zhang D, Wu B, Luo M (2017) Residual stresses analysis in ball end milling of nickel-based Superalloy Inconel 718. Mater Res
https://doi.org/10.1590/1980-5373-mr-2017-0561 Copyright information
© Springer-Verlag London Ltd., part of Springer Nature 2018