Modeling of Residual Stress and Machining Distortion in Aerospace Components

2010 ◽  
pp. 386-407
Keyword(s):  
Residual Stress ◽  
Machining Distortion

Study on the Residual Stresses Distribution in Thick Pre-Stretched Aluminum Plate

2018 ◽  
Vol 764 ◽  
pp. 49-57
Author(s):  
Hun Guo ◽  
Dun Wen Zuo ◽  
Fei Hong Yin ◽  
Ya Feng He ◽  
Ji Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Quantitative Analysis ◽  
Residual Stresses ◽  
Thick Plate ◽  
Engineering Application ◽  
Machining Distortion ◽  
Stress Strain Relation ◽  
Measurement Results ◽  
Aluminum Plates

It is one of the difficult problems in the manufacture of the integrated aircraft part of Machining distortion caused by residual stress. According to the characteristics of aluminum alloy pre stretched thick plate, the modified removal method for measuring residual stress in thick pre-stretched aluminum plates is proposed and the stress-strain relation matrix is deduced by elasticity theory. Moreover, the residual stresses in the specimen of 7075T7351 plate is measured by the proposed method, and the results are finally analyzed and compared with the data obtained by other methods. The results indicate that the proposed method is effective in measuring the residual stress in thick pre-stretched aluminum alloy plates. The measurement results can be used for the quantitative analysis of aerospace parts machining distortion caused by residual stress, and it has higher value in engineering application.

Numerical Simulation of Machining Distortion of Residually Stressed Aircraft Aluminum Components

2006 ◽  
Vol 315-316 ◽  
pp. 235-238 ◽  
Author(s):  
Q.C. Wang ◽  
Xiao Dong Hu ◽  
W. Li ◽  
Ju Long Yuan
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Energy Density ◽  
Square Root ◽  
Stress Range ◽  
Key Factors ◽  
Machining Distortion ◽  
Simulation Results ◽  
Aluminum Component ◽  
Good Agreement

The presence of residual stress in aircraft aluminum components can give rise to distortion after machining. Excessive distortion may result in the rejection of a part or the need for costly and time-consuming rework prior to placement in service. The purpose of this research was to develop a methodology for the prediction of machining-induced distortions of residually stressed aircraft aluminum components. Numerical simulation results show that the magnitude of machining distortion is strongly related to the square root of Stain Energy Density W or Stress Range σ . The experimental results demonstrate good agreement with the predicted machining distortions of 7075T73 bulkheads. It included that the original residual stress in the blocks of aircraft aluminum component is one of key factors to cause machining distortion.

scholarly journals Influence of heat treatment on the residual stress-related machining distortion of Ti-6Al-4V alloy monolithic parts

Procedia CIRP ◽  
2021 ◽  
Vol 104 ◽  
pp. 1328-1333
Author(s):  
M. Landwehr ◽  
F. Oehler ◽  
H. Behnken ◽  
H. Holling ◽  
R. Sambathkumar ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Machining Distortion

scholarly journals Study on the Machining Distortion of Thin-walled Part Caused by Redistribution of Residual Stress

2005 ◽  
Vol 18 (2) ◽  
pp. 175-179 ◽  
Author(s):  
Zhao-jun WANG ◽  
Wu-yi CHEN ◽  
Yi-du ZHANG ◽  
Zhi-tong CHEN ◽  
Qiang LIU
Keyword(s):  
Residual Stress ◽  
Machining Distortion ◽  
Thin Walled

Analysis of the Milling Distortion due to Residual Stress Based on Analytical Method

2010 ◽  
Vol 33 ◽  
pp. 88-91
Author(s):  
Yuan Wei Liu
Keyword(s):  
Residual Stress ◽  
Elasticity Theory ◽  
Analytical Method ◽  
Milling Process ◽  
Theory Theory ◽  
Machining Distortion

Formulae of stress re-distribution and distortion by stress releasing during milling process are deduced by elasticity theory. Theory prediction of milling deformation due to residual stress is finished, and some calculating equation is given for the deformation solution. By means of these researches, the mechanism of the milling deformation due to residual stress is analyzed, the machining distortion caused by residual stress are analyzed and summarized using the analytical method.

Influences of Initial Residual Stresses on Milling Distortion for Thick Aero-Aluminum-Alloy Plate

2011 ◽  
Vol 381 ◽  
pp. 44-47
Author(s):  
Hun Guo ◽  
Dun Wen Zuo ◽  
Guo Xing Tang ◽  
W.M. Gan
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Residual Stresses ◽  
Analytical Method ◽  
Milling Process ◽  
Alloy Plate ◽  
Machining Distortion ◽  
Aluminum Alloy Plate

Formulae of stress re-distribution and distortion by stress releasing during milling process are deduced to Initial Residual Stresses. Theory prediction of milling deformation due to residual stress is finished, and some calculating equation is given for the deformation solution. By means of these researches, the mechanism of the milling deformation due to residual stress is analyzed, the machining distortion caused by residual stress are analyzed and summarized using the analytical method.

Study on Machining Distortion of Residual Stress Release

2012 ◽  
Vol 426 ◽  
pp. 143-146 ◽  
Author(s):  
Jie Chen
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Material Removal ◽  
High Speed ◽  
Key Factors ◽  
Stress Release ◽  
High Speed Milling ◽  
Machining Distortion ◽  
Element Simulation ◽  
Aluminum Component

When machining multi-frame complex components, more than 90% of the materials would be removed, resulting in severe distortion of the parts due to the weakened rigidity and the release of residual stress. This might also lead to stress concentration and damage of the parts. The effect of material removal from residually stressed billet is simulated using FEA software ANSYS, and the causations of distortion is analyzed. To verify the finite element simulation, a high speed milling test on aluminum alloy 7050T7351 is carried out. The results show that the simulation result is consistent with the experimental one. It included that the original residual stress in the blocks of aero-aluminum component is one of key factors to cause machining distortion.

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