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Analytical modeling of machining-induced residual stresses in milling of complex surface

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Abstract

The distribution of residual stresses has a significant effect on fatigue life in milling process. In previous works, the predicted model of residual stresses was focusing on orthogonal cutting, while milling residual stresses is seldom reported. An analytical model for the generation of residual stresses induced by complex surface milling is proposed. Estimates of the mechanical stresses induced by the milling process have been determined through contact mechanics and the geometric transformations within the part. The temperature field of workpiece induced by milling is predicted by analytical model. Estimates of the residual stresses were obtained using an elastic-plastic model and a relaxation procedure. The proposed model is validated with milling experiments. This work can be further applied to improve surface integrity of workpieces by machining parameters optimization.

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Funding

This work is supported by the National Key Basic Research Program of China (no. 2014CB046704) and Key Projects in the National Science Technology Pillar Program of China (no. 2014BAB13B01).

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Authors and Affiliations

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

    Ruihu Zhou & Wenyu Yang

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  1. Ruihu Zhou
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  2. Wenyu Yang
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Correspondence to Wenyu Yang.

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Zhou, R., Yang, W. Analytical modeling of machining-induced residual stresses in milling of complex surface. Int J Adv Manuf Technol 105, 565–577 (2019). https://doi.org/10.1007/s00170-019-04219-7

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  • DOI: https://doi.org/10.1007/s00170-019-04219-7

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