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Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation

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Abstract

Press-braking bending is usually performed after face milling to obtain the specified curvature of variety mechanical parts, which is widely applied in the aircraft manufacturing. However, the residual stress on the surface layer of the workpiece resulting from the milling process can significantly impact the subsequent bending forming. This paper aims to investigate the influences of surface residual stress caused by milling operation on press-braking bending both analytically and experimentally. An analytical model for springback prediction based on plane strain assumption is proposed using the material model of Mises yield criterion and Swift exponential hardening law, while also considering the effects of milling-induced residual stress. Three different levels of residual stress are introduced into the test plates through milling operation at varying cutting speed. The analytical results are then compared with bending experiments conducted on 7050-T7451 Al-alloy plates. Results show that the accuracy of the predicted contour is improved when surface residual stress is taken into account. Furthermore, the influence of surface residual stress on springback is discussed. It is revealed that surface tensile residual stress increases springback, while surface compressive residual stress contributes positively to the final shape of bent specimens.

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Funding

This work is funded by the Natural Science Basic Research Project of Shaanxi Province, China (grant number 2022JQ-526); the Key Laboratory of Road Construction Technology and Equipment of MOE, Chang’an University (grant number 300102252508); and the Doctoral Foundation Project of Xi’an Polytechnic University (grant number BS202121).

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  1. School of Mechanical and Electrical Engineering, Xi’an Polytechnic University, Xi’an, China

    Min Zhang & Dongming Li

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  1. Min Zhang
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  2. Dongming Li
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by M.Z. and D.L. The first draft of the manuscript was written by M.Z., and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Min Zhang.

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Zhang, M., Li, D. Theoretical and experimental investigation of the deformation shape in press-braking bending considering surface residual stresses induced by milling operation. Int J Adv Manuf Technol 131, 1059–1069 (2024). https://doi.org/10.1007/s00170-024-13089-7

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  • DOI: https://doi.org/10.1007/s00170-024-13089-7

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