Elastic-Plastic Deformation of Milling Thin Wall Part

2013 ◽  
Vol 345 ◽  
pp. 321-324
Author(s):  
Ai Jun Tang ◽  
Hai Long Ma ◽  
Zhan Qiang Liu
Keyword(s):  
Plastic Deformation ◽  
End Milling ◽  
High Accuracy ◽  
Fe Analysis ◽  
Deformation Model ◽  
Thin Wall ◽  
Deformation Prediction ◽  
Elastic Plastic ◽  
Very High ◽  
Thin Wall Part

Aircraft components are mostly made by aluminum alloy as thin wall types. These parts are usually end milled to required thicknesses and tight tolerances in specific areas. The thin wall parts are difficult to machine because they are easy to vibrate and deformed due to their lower rigidity. This paper proposes a new elastic-plastic deformation model which is suitable for prediction of machining deformations of end milled thin wall parts. The theoretical deformation model is established on the basis of the equations of Von Kármán. The part deformations are simulated using FE analysis and Matlab. The results show that the deformations for the end milling of thin wall parts can be captured with very high accuracy using the proposed elastic-plastic deformation prediction model.

Experiments and Simulation of Elastic-Plastic Deformation in Thin Wall Part Milling

2011 ◽  
Vol 314-316 ◽  
pp. 482-486 ◽  
Author(s):  
Ai Jun Tang ◽  
Zhan Qiang Liu
Keyword(s):  
Plastic Deformation ◽  
Cnc Machining ◽  
Deformation Model ◽  
Thin Wall ◽  
Peripheral Milling ◽  
Deformation Prediction ◽  
Elastic Plastic ◽  
Machining Center ◽  
Cnc Machining Center ◽  
Thin Wall Part

Aircraft components are mostly made by aluminum alloy as thin wall types. These parts are usually end milled to required thicknesses and tight tolerances in specific areas. The thin wall parts are difficult to machine because they are easy to vibrate and deformed due to their lower rigidity. This paper proposes a new elastic-plastic deformation model which is suitable for prediction of machining deformations of end milled thin wall parts. The theoretical deformation model is established on the basis of the equations of Von Kármán. The effect of bending springback is also taken into account. The part deformations are simulated using FE analysis and Matlab. Milling experiments on a CNC machining center are performed. The experimental results show that the deformations for the peripheral milling of thin wall parts can be captured with very high accuracy using the proposed elastic-plastic deformation prediction model.

scholarly journals Precise Machining Based on Ritz Non-uniform Allowances for Titanium Blade Fabricated by Selective Laser Melting

2021 ◽  
Author(s):  
Bo Zhang ◽  
Juntang Yuan ◽  
zhenhua wang ◽  
Xi Li
Keyword(s):  
Selective Laser Melting ◽  
End Milling ◽  
Deformation Model ◽  
Thin Wall ◽  
Laser Melting ◽  
Machining Processes ◽  
Element Analysis ◽  
Surface Error ◽  
Wall Stiffness ◽  
Finishing Machining

Abstract Selective Laser Melting (SLM) is an increasingly concerned trend in Ti-6Al-4V blade manufacturing, while the SLMed Ti-6Al-4V blade cannot be used directly because of poor surface integrity and high residual stresses. Precise machining after SLM is a feasible solution but also a challenge. The low rigidity of the blade will lead to deformation when machining. The deformation can lead to surface error and may make defect parts. Two-steps machining processes to address the problems were proposed in this paper. First, a non-uniform allowance distribution was allocated and optimized in semi-finishing based on Ritz solution to elastic deformation. The blade was simplified as a cantilever thin plate with various thickness, and the thickness of finishing allowance was designed and optimized on the premise of ensuring the thin-wall stiffness of the blade, so as to realize the design of Ritz non-uniform allowance. Then, finishing machining was conducted to achieve precise parts. A blade deformation model was established to evaluate surface error with cutting force moving and changing. Finite element analysis and experimental validation in ball-end milling of a blade were conducted. FEA results and experimental results showed dimensional errors have been reduced up to 50%. Further surface tests demonstrated that the mean surface roughness reduced from 7.88 μm to 0.815 μm. And the residual surface stresses of the SLM samples changed after semi-finishing machining due to the residual stress relaxation and redistribution. The results demonstrated that the proposed method enhanced the surface quality of blade fabricated by SLM.

scholarly journals Incompatible Deformation Model of Rocks with Defects around a Thick-Walled Cylinder

Processes ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 2215
Author(s):  
Yingji Bao ◽  
Binsong Jiang
Keyword(s):  
Plastic Deformation ◽  
Strain Tensor ◽  
Continuum Theory ◽  
Plastic State ◽  
Deformation Model ◽  
Underground Engineering ◽  
Metric Tensor ◽  
Finite Element Program ◽  
Elastic Plastic ◽  
Walled Cylinder

Before the excavation of underground engineering, joints, fissures, and voids already exist in the rock—that is, there are defects in the rock. Due to the existence of these defects, the rock produces plastic deformation, which can lead to incompatible deformation. Therefore, the classic continuum theory cannot accurately describe the deformation of the rock. In this paper, a relationship between the strain tensor and metric tensor was studied by analyzing the three states of elastic plastic deformation, and the elasto-plastic incompatible model was built. Additionally, the stress and deformation of a thick-walled cylinder under hydrostatic pressure was investigated by using a finite element program written in the FORTRAN language. The results show that the plastic strain is associated with not only deviator stress but also the distribution of defects (represented by the incompatible parameter R). With the value of R increasing, the defects in the rock increased, but the elastic plastic stiffness matrix decreased. Thus, as more rock enters the plastic state, the deformation of the surrounding rock is enlarged.

Grain Refinement and Strengthening of Aluminum Alloys: Cold Severe Plastic Deformation Model

2019 ◽  
Author(s):  
Xiao Guang Qiao ◽  
Nong Gao ◽  
Marco Starink
Keyword(s):  
Plastic Deformation ◽  
Grain Size ◽  
Grain Refinement ◽  
Aluminium Alloys ◽  
Cold Deformation ◽  
Al Alloys ◽  
Deformation Model ◽  
Angular Pressing ◽  
Dislocation Movement ◽  
Very High

This paper presents a model which quantitatively predicts grain refinement and strength/hardness of Al alloys after very high levels of cold deformation through processes including cold rolling, equal channel angular pressing (ECAP), multiple forging (MF), accumulative rolling bonding (ARB) and embossing. The model deals with materials in which plastic deformation is exclusively due to dislocation movement, which is in good approximation the case for aluminium alloys. In the early stages of deformation, the generated dislocations are stored in grains and contribute to overall strength. With increase in strain, excess dislocations form and/or move to new cell walls/grain boundaries and grains are refined. We examine this model using both our own data as well as the data in the literature. It is shown that grain size and strength/hardness are predicted to a good accuracy.

An algorithm for region extraction based on an elastic-plastic deformation model

2001 ◽  
Vol 32 (5) ◽  
pp. 46-54
Author(s):  
Mikito Ikuta ◽  
Akihiro Minagawa ◽  
Toshiyuki Gotoh
Keyword(s):  
Plastic Deformation ◽  
Deformation Model ◽  
Elastic Plastic ◽  
Region Extraction

Identification and Simulation of Elastic-Plastic Deformation Model

2005 ◽  
Vol 482 ◽  
pp. 315-318 ◽  
Author(s):  
Łukasz Maciejewski ◽  
Wojciech Myszka ◽  
Grażyna Ziętek
Keyword(s):  
Plastic Deformation ◽  
Deformation Model ◽  
Elastic Plastic

FE Analysis on Rolls Deformation in Rolling Process of 4100 Heavy Plate Mill

2012 ◽  
Vol 562-564 ◽  
pp. 631-634
Author(s):  
Xue Tong Li ◽  
Min Ting Wang ◽  
Feng Shan Du ◽  
Yong Gang Cui
Keyword(s):  
Finite Element Method ◽  
Plastic Deformation ◽  
Finite Element ◽  
Rolling Process ◽  
Fe Analysis ◽  
Fe Model ◽  
Plate Mill ◽  
Elastic Plastic ◽  
Heavy Plate ◽  
Roll Gap

Against 4100 heavy plate miller, a 3-D rolling model involving rolls’ elastic deformation and workpiece’s elastic-plastic deformation is established using large deformation elastic-plastic finite element method. The distributions of the rolls’ bending deformation and the roll gap shape by simulation under the different processes. The results can provide the practical referential value for equipment design and processing setup of heavy plate mill. The FE model may be used to analyze skinning process on off-line.

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