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

2020 ◽  
Vol 110 (1-2) ◽  
pp. 139-161 ◽  
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

Residual Stress Regenerated on Low Plasticity Burnished Inconel 718 Surface After Initial Turning Process

2019 ◽  
Vol 141 (12) ◽  
Author(s):  
Yang Hua ◽  
Zhanqiang Liu ◽  
Bing Wang ◽  
Jiaming Jiang
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Analytical Model ◽  
Inconel 718 ◽  
Plastic Behavior ◽  
Residual Stress Field ◽  
Workpiece Material ◽  
Elastic Plastic ◽  
Initial Residual Stress ◽  
Low Plasticity Burnishing

Abstract Low plasticity burnishing (LPB) has been extensively employed in aero-industry to enhance fatigue performance of machined components by introducing compressive residual stress. Effects of various parameters on the residual stress field induced by low plasticity burnishing have been investigated by many researchers. However, initial residual stresses induced by machining are one of the important factors which affect the residual stress regenerated by the LPB process. The present work aims to develop an analytical model which takes into account the initial residual stress and burnishing parameters to predict residual stress field of workpiece material Inconel 718 based on Hertz contact theory and elastic–plastic theory. Initial residual stress fields were produced by turning of Inconel 718 and were measured by using X-ray diffraction technique. Two types of material constitutive models such as the linear hardening model and isotropic–kinematic model were employed to describe the elastic–plastic behavior of workpiece material Inconel 718. An analytical study was performed to analyze the effect of the initial residual stress field and burnishing parameters on residual stress induced by low plastic burnishing. The results of analytical model were verified by conducting the LPB experiments on initial turned Inconel 718. The results showed that the shape and magnitude of the residual stress field obtained with considering the effect of initial residual stress field was in good accordance with experimental measurements.

An analytical model to predict the machining deformation of frame parts caused by residual stress

2019 ◽  
Vol 274 ◽  
pp. 116282 ◽  
Author(s):  
Zibiao Wang ◽  
Jianfei Sun ◽  
Liangbao Liu ◽  
Rongqiao Wang ◽  
Wuyi Chen
Keyword(s):  
Residual Stress ◽  
Analytical Model ◽  
Machining Deformation

Deformation Control and Chatter Suppression in 5-Axis Milling of Thin-Walled Blade

2011 ◽  
Vol 188 ◽  
pp. 314-318
Author(s):  
Bao Hai Wu ◽  
Ming Luo ◽  
Ding Hua Zhang ◽  
X. Zhou
Keyword(s):  
Residual Stress ◽  
Deformation Control ◽  
Tool Paths ◽  
Machining Quality ◽  
Chatter Suppression ◽  
Machining Deformation ◽  
Thin Walled

This paper deals with deformation control and chatter suppression in the milling of thin-walled blade. The purpose is to generate tool paths that can control machining deformation and suppress chatter during milling. To achieve this object, symmetrical spiral milling approach is proposed to release residual stress on both sides of the blade in the same machining circle to control machining deformation. Besides, in order to suppress chatter during milling of thin-walled blade, nonuniform-allowance is left on both sides of the blade during machining, this can effectively increase the rigidity, thereby chatter cannot easily occur during machining. Machining experiments showed that the proposed approaches can dramatically improve the machining quality, decrease deformation and suppress chatter in the milling of thin-walled blade.

Optimization of Bulkhead Processing Sequence for Multi-Frame Monolithic Components by FEM

2007 ◽  
Vol 24-25 ◽  
pp. 355-360 ◽  
Author(s):  
Zhi Tao Tang ◽  
Zhan Qiang Liu ◽  
Xing Ai
Keyword(s):  
Residual Stress ◽  
Material Properties ◽  
Element Model ◽  
Clamping Force ◽  
Processing Sequence ◽  
Initial Residual Stress ◽  
Machining Deformation ◽  
Proposed Model ◽  
Key Techniques ◽  
Monolithic Components

When machining aerospace monolithic components, most of materials could be removed, resulting in severe deformation of the parts due to the release and redistribution of the blank’s original residual stress, together with the action of cutting loads and clamping force. A finite element model (FEM) is built for predicting the deformation caused by those factors mentioned above. In this model, some key techniques such as material properties, initial residual stress model, and application of dynamic cutting loads and transformation of boundary condition are discussed in details. The proposed model predicts the machining deformation for multi-frame monolithic components. Particular attention is paid to the influence of the bulkhead processing sequence on part deformation. At last the paper puts forwards optimal bulkhead processing sequence based on minimizing the machining deformation.

Deformation Mechanism and Characteristics of Thin-Walled Component in Aluminum Alloy

2016 ◽  
Vol 838-839 ◽  
pp. 237-242
Author(s):  
Kai Liao ◽  
Fei Chen ◽  
Yi Peng Liu
Keyword(s):  
Residual Stress ◽  
Bending Moment ◽  
Deformation Characteristics ◽  
Initial Residual Stress ◽  
Simulation And Experiment ◽  
Thin Walled ◽  
Component Shape ◽  
Stress And Deformation ◽  
Minimum Distortion ◽  
Residual Stress And Deformation

During milling of thin-walled components, obtaining minimum distortion is essential in order to achieve production goals. In this study, a mechanical model based on deformation machanism is established, and is help to analyse relationship between residual stress and deformation in component. Researched on simulation and experiment, the stress-deformation characteristics of different component shape is obtained. The results indicate that the deformation of thin-walled component in milling primarily depends on the distribution of initial residual stress, which can generate bending moment and lead to distortion. And then milling stress on the surface is easy to make bending moment baesd on this distortion, and make the deformation of component intensify.

Machining path research of thin-walled parts considering initial residual stress

2020 ◽  
Vol 15 (4) ◽  
pp. 344
Author(s):  
Yunan Liu ◽  
Min Wang ◽  
Xiangsheng Gao ◽  
Lili Wu ◽  
Xiaodong Jiang
Keyword(s):  
Residual Stress ◽  
Initial Residual Stress ◽  
Thin Walled

Numerical Simulation Investigation on Machining Deformation of Aviation Thin-Walled Parts Caused by Residual Stress

2021 ◽  
Vol 1032 ◽  
pp. 186-191
Author(s):  
Jie Deng ◽  
Shi Jie Zhou ◽  
Han Jun Gao ◽  
Ming Hui Lin ◽  
Xin Li
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Residual Stresses ◽  
Simulation Models ◽  
Cutting Parameters ◽  
Stress Distributions ◽  
Machining Deformation ◽  
Proposed Model ◽  
Thin Walled ◽  
Structural Parts

Holistic thin-walled parts are common structural parts of modern aircraft to reduce the weight and increase the stiffness. Over 90% of the materials are removed from the blank, as a result, large machining deformations occur to the parts, which causes the manufacturing discrepancies and even the scrap parts. In this paper, numerical simulation models are established to predict the machining deformation of two typical aviation thin-walled parts. The blank initial and machining induced residual stresses, as well as the cutting parameters, are considered in the model. The deformations and stresses after machining are calculated using the proposed model, and the deformation and stress distributions are analyzed.

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