Abstract
In the manufacturing process of aerospace large ring parts, a large number of exterior materials are removed, which makes the ring parts become a thin-walled structure with low stiffness. In the actual production process of the aerospace industry, the processing deformation caused by a series of internal and external factors is ubiquitous. The studies show that the main factor causing the machining deformation is the initial residual stress (RS) inside the blank ring. The ring rolling process is accompanied by local severe plastic deformation, resulting in large and uneven RS. The homogenization and reduction of initial RS are of great significance to reduce the adverse effect of machining deformation. The research object in this study is a sizeable GH4169 alloy aerospace rolling ring. First, a long-term natural ageing treatment was designed for homogenizing residual stresses in sizeable GH4169 alloy ring. Second, a finite element model was established to simulate the rolling process and the thermal ageing process. The corresponding rolling and thermal ageing experiments were carried out to verify the simulation results. The purpose of this process is to explore and verify the effect of natural ageing and artificial ageing on homogenizing and reducing the RS in the rolling ring. The results show that the homogenization of RS distribution was enhanced significantly by natural ageing treatment, while the RS magnitudes descended by 15~35%. Combined with the subsequent thermal stress relief, the RS is significantly reduced or even eliminated. This study is of great significance to the homogenization and reduction of RS in large GH4169 alloy ring.
Similar content being viewed by others
Data availability
The authors confirm that the data supporting the findings of this study are available within the article.
References
Williams JC, Starke EA (2003) Progress in structural materials for aerospace systems. Acta Mater 51(19):5775–5799
Jinhui DU, Xudong LU, Deng Q et al (2012) Progress in GH4169 alloy development. Mater China 31(12):12–20
Prime MB, Hill MR (2002) Residual stress, stress relief, and inhomogeneity in aluminum plate. SCRIPTA MATER 46(1):77–82
Zheng Y, Wang J, Wang M et al (2016) Study in machining deformation rule of integral casing structure parts based on supplemental support. Mach Tool Hydraul
Srivatsa SK, Aviation GE (2010) Modeling of residual stress and machining distortion in aerospace components. Cdn.intechopen.com. AFRL-RX-WP-TP-2010-4148
Lam ACL, Shi Z, Lin J, Huang X (2015) Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming. Int J Mech Ences 103:115–126
Wei Y, Wang XW (2007) Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts. Int J Adv Manuf Technol 33(3–4):260–265
Cerutti X, Mocellin K et al (2015) Parallel finite element tool to predict distortion induced by initial residual stresses during machining of aeronautical parts. Int J Mater Form 8(2):1–14
Zhao-jun WANG, Wu-yi CHEN, Yi-du ZHANG et al (2005) Study on the machining distortion of thin-walled part caused by redistribution of residual stress. Chinese J Aeronaut 18(2):175–179
Wu Q, Li DP (2014) Analysis and X-ray measurements of cutting residual stresses in 7075 aluminum alloy in high speed machining. Int J Precis Eng Manuf 15(8):1499–1506
Robinson JS, Tanner DA, Van Petegem S et al (2012) Influence of quenching and aging on residual stress in Al-Zn-Mg-Cu alloy 7449. Mater Ence Technol 28(4):420–430
Drezet JM, Evans A, Pirling T, Pitié B (2012) Stored elastic energy in aluminium alloy AA 6063 billets: residual stress measurements and thermomechanical modelling. Cast Metals 25(2):110–116
Abvabi A, Rolfe B, Hodgson PD et al (2015) The influence of residual stress on a roll forming process. Int J Mech Ences 101–102:124–136
Hassani-Gangaraj SM, Carboni M, Guagliano M (2015) Finite element approach toward an advanced understanding of deep rolling induced residual stresses, and an application to railway axles. Mater Des 83(oct.15):689–703
Gong H, Yun-Xin WU, Liao K (2009) Influence of pre-stretching on residual stress distribution in 7075 aluminum alloy thick-plate.T Mater Heat Treat 30(6):201–205
Sun Y, Jiang F, Zhang H, Su J, Yuan W (2016) Residual stress relief in Al–Zn–mg–cu alloy by a new multistage interrupted artificial aging treatment. Mater Des 92(Feb.):281–287
Wu Q, Wu J, Zhang Y et al (2019) Analysis and homogenization of residual stress in aerospace ring rolling process of 2219 aluminum alloy using thermal stress relief method. Int J Mech Sci 157–158:111–118
Junjie X, Dongsheng L, Xiaoqiang L (2015) Modeling and simulation for the stress relaxation behavior of Ti-6Al-4V at medium temperature. Rare Metal Mater Eng 44(5):1046–1051
Yafei LI, Ou DI (2015) Research on effects of vibration aging on removal of residual stress in aluminum alloy forgings. Hot Working Technology
Cheng HM, Yang C, Wang LM et al (2008) Residual stress measurement and analysis of gray cast iron with different Si/C ratio. Hot Working Technology 29(11):1494–1497 (In China)
Zhou S, Ji Z, Shao T (2015) Residual stress evolution during long-term and cyclic aging and annealing of gold films deposited by electron beam evaporation. VACUUM 120:132–138
Committee CAMM (1989) China Aviation Materials Manual, 2nd edn. In Wrought superalloy and cast superalloy. Standards Press of China, pp 324–326 (In China)
Lu HJ, Jia XC, Zhang KF et al (2002) Effect of superfine - graining on mechanical properties of superalloy GH4169. Mater Ence Technol 10(3):268–271
Xuefeng L, Yurong Y, Biao S et al (1996) The changes of the microstructure and mechanical properties of the GH169 disks for long aging. J Mater Eng (01):23–25 (In China)
Institute Of Aeronautical Material B (2010) Material data book for Aeroengine Design. 91–170
Schajer GS (1988) Measurement of non-uniform residual stresses using the hole-drilling method. Part I—stress calculation procedures. J Eng Mater Technol ASME 110(4):115–119
Schajer GS (1988) Measurement of non-uniform residual stresses using the hole-drilling method. Part II—practical application of the integral method. J Eng Mater Technol ASME 110(4):115–119
Gibmeier J, Kornmeier M, Scholtes B (2000) Plastic deformation during application of the hole-drilling method
Steinzig M, Upshaw D, Rasty J (2014) Influence of drilling parameters on the accuracy of hole-drilling residual stress measurements. Exp Mech 54(9):1537–1543
Abbas NM, Solomon DG, Bahari MF (2016) A review on current research trends in electrical discharge machining (EDM). Int J Mach Tool Manu 47(7–8):1214–1228
Jinhui D, Xudong L, Qun D (2014) Effect of heat treatment on microstructure and mechanical properties of GH4169 Superalloy. Rare Metal Mat Eng 43(8):1830–1834
Aba-Perea PE, Pirling T, Preuss M (2016) In-situ residual stress analysis during annealing treatments using neutron diffraction in combination with a novel furnace design. Mater Des 110:925–931
Funding
The study leading to these results has received funding from the Key Research and Development Program of Shaanxi Province (No.2020GY-253) and the Natural Science Basic Research Program of Shaanxi Province (No.2020JQ-182).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Competing interests
The authors declare that they have no competing interests.
Ethical approval
Not applicable.
Consent to participate
Not applicable.
Consent to publish
Not applicable.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Lv, N., Liu, D., Yang, Y. et al. Studying the residual stress homogenization and relief in aerospace rolling ring of GH4169 alloy using ageing treatment. Int J Adv Manuf Technol 112, 3415–3429 (2021). https://doi.org/10.1007/s00170-021-06612-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06612-7