Machining deformation prediction of large fan blades based on loading uneven residual stress

In the process of metal parts fabricated by Laser Melting Deposition (LMD), a high temperature gradient will generate due to the instantaneous high laser energy input, which will cause residual stress in the formed part of metal parts, the residual stress will result in defects like warping deformation or even cracking. In this paper, a finite element method based on inherent strain method is proposed to predict the deformation of metal parts fabricated by LMD. Firstly, combing with the birth and death element technology, a local model is established to simulate the layer-by-layer deposition in the LMD forming process, and the values of inherent strain is obtained. Secondly, the obtained inherent strain values is applied to large-sized part layer by layer, and the final deformation of large-sized part is calculated. Based on the proposed method, the efficiency of deformation prediction of large-sized metal parts fabricated by LMD could be effectively improved.

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Macro-Residual Stress Field Retrieval for Predicting the Machining Deformation of Non-Prestretched Plate

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.317-319.386 ◽

2011 ◽

Vol 317-319 ◽

pp. 386-392

Author(s):

Yin Fei Yang ◽

Ning He ◽

Liang Li

Keyword(s):

Residual Stress ◽

Stress Field ◽

Large Scale ◽

Hole Drilling ◽

Residual Stress Field ◽

Hole Drilling Method ◽

Machining Deformation ◽

Stress Changes ◽

Drilling Method ◽

And Control

The unknown and uneven macro-residual stresses in blanks will cause deformation on large-scale component, especially in non-prestretched plates. Based on the retrieval of stress field by measuring stress changes due to the rebalance of stresses after machining, a new idea is proposed in this paper to predict and control the machining deformation of large-scale components. It consists of analysis of the machining deformation, retrieval of macro-residual stress field, and finally optimization of following cutting process. In the retrieval process, the stresses are measured with an improved hole-drilling method and the measured data are then interpolated to 3D stress field.

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Research on the Machining Deformation Based on Release of Inner Residual Stress of Material

2010 International Conference on Intelligent System Design and Engineering Application ◽

10.1109/isdea.2010.371 ◽

2010 ◽

Author(s):

Xiaohang Wan ◽

Shengyong Liu ◽

Zhaowei Dong

Keyword(s):

Residual Stress ◽

Machining Deformation

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A semi-analytical model for predicting the machining deformation of thin-walled parts considering machining-induced and blank initial residual stress

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-05862-1 ◽

2020 ◽

Vol 110 (1-2) ◽

pp. 139-161 ◽

Cited By ~ 1

Author(s):

Bianhong Li ◽

Hongbin Deng ◽

David Hui ◽

Zheng Hu ◽

Wanhao Zhang

Keyword(s):

Residual Stress ◽

Analytical Model ◽

Initial Residual Stress ◽

Machining Deformation ◽

Thin Walled

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Research on Overall Aluminum Alloy Flange Machining Deformation

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.436 ◽

2016 ◽

Vol 836-837 ◽

pp. 436-443 ◽

Cited By ~ 2

Author(s):

Xiang Dong Qi ◽

Wei Zhang ◽

Hui Tian ◽

Xiao Wei Zheng ◽

Kai Qin Yu ◽

...

Keyword(s):

Residual Stress ◽

Aluminum Alloy ◽

Material Removal ◽

Machining Deformation ◽

Deformation Law ◽

Machining Allowance ◽

Bottle Neck ◽

Processing Control ◽

Structural Parts ◽

The Comparative Study

Machining deformation has been a bottle-neck issue in aeronautical manufacturing field. Due to the large amount of material removal and other issues, machining deformation is predicted more difficultly during the process of 2026-T3511 aluminum alloy rim. Hence a simple full-size model of margin monolithic was built to study the deformation under the influence of residual stress releasing. The process of the structural parts was simulated and the deformation law of overall structure considering residual stress releasing only was revealed. Through the comparative study of different machining processing, control strategy reducing the final part machining deformation and optimum machining allowance range were proposed.

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