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Investigation of residual impact stress and its effects on the precision during milling of the thin-walled part

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Abstract

Residual stress has a lasting effect on the deflection of machined thin-walled parts, which also strictly restricts the use of products. This paper finds that there exists residual impact stress during the high-speed cutting machining of thin-walled parts, which is very unfavorable to the quality of thin-walled parts. Obvious residual impact stress exists during the cutting-in and cutting-out stages, while stable machining residual stress exists in the middle stage. At the cutting-in and cutting-out positions of tool, the residual impact stress generated by a parameter combination of low speed, large feed, and large depth of cut is much smaller than that generated by other combinations of process parameters. The residual impact stress on multiple machined surfaces can propagate on the surface to form distribution with equal stress energy areas. By increasing the linear cutting speed, the surface and subsurface residual stress values can be decreased to some extent. Although the cutting efficiency improves, the deflection caused by residual stress reduces. Based on these results, experimental verification is carried out on the thin-walled parts. And the evidence shows the presented approach is useful to reduce the residual impact stresses; therefore, distortion of thin-walled part is also within control.

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Funding

This paper is supported by National Natural Science Foundation of China (Grant No. 51505291).

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Authors and Affiliations

  1. College of Mechanical Engineering, University of Shanghai for Science and Technology, Yangpu, Shanghai, 200093, People’s Republic of China

    Xiaohui Jiang, Yihong Zhu, Zhenya Zhang, Miaoxian Guo & Zishan Ding

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  1. Xiaohui Jiang
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  2. Yihong Zhu
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  3. Zhenya Zhang
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  4. Miaoxian Guo
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  5. Zishan Ding
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Correspondence to Xiaohui Jiang.

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Jiang, X., Zhu, Y., Zhang, Z. et al. Investigation of residual impact stress and its effects on the precision during milling of the thin-walled part. Int J Adv Manuf Technol 97, 877–892 (2018). https://doi.org/10.1007/s00170-018-1941-x

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  • DOI: https://doi.org/10.1007/s00170-018-1941-x

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