Abstract
Residual stress has a sustained impact on the deformation of thin-walled parts after processing, raising the strict restrictions required in their using procedure. In general, with regard to thin-walled parts, different processing parameters will affect the distortion and residual stress generation of the workpiece, which play the key role in the machining. However, controlling the material removal rate is also quite critical to machining of thin-walled parts. In order to reach these goals, based on the relation between residual stress and uncut chip thickness (UCT), a method is proposed by optimizing the milling tool diameters. The research finding reveals that, by improving the tool diameter, at the same circular position, smaller UCT can be achieved. In addition, take 6 and 12 mm tool diameter as analysis cases; larger tool diameter can reduce the residual tensile stress distribution significantly (the ratio ranges from 13.9 to 34.7 %) and improve the material removal rate. Moreover, a typical thin-walled part is evaluated using different tool diameters (6 and 12 mm) by experiments, as the final distortion can be decreased by 60 % with 12-mm tool diameter. The distribution of machined surface and subsurface residual stress is turning to be more uniform. Hence, it proves that, under the goals of maintaining machining accuracy and material removal rate, also improving the distribution of residual stress, it is possible to achieve by controlling the UCT (tool diameters) in the processing of thin-walled. All these findings can help to enhance the milling precision of thin-walled parts, as well as control and optimize the residual stress distribution.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Li JL, Jing LL, Chen M (2009) An FEM study on residual stresses induced by high-speed end-milling of hardened steel SKD11. J Mater Process Technol 209:4515–4520
Guo YB, Barkey ME (2004) FE-simulation of the effects of machining-induced residual stress profile on rolling contact of hard machined components. Int J Mech Sci 46:371–388
Zong WJ, Li D, Cheng K, Sun T, Liang YC (2007) Finite element optimization of diamond tool geometry and cutting-process parameters based on surface residual stresses. Int J Adv Manuf Technol 32:666–674
Özel T, Zeren E (2007) Finite element modeling the influence of edge roundness on the stress and temperature fields induced by high-speed machining. Int J Adv Manuf Technol 35:255–267
El-Axir MH (2002) A method of modeling residual stress distribution in turning for different materials. Int J Mach Tools Manuf 42:1055–1063
Ulutan D, Alaca BE, Lazoglu I (2007) Analytical modeling of residual stresses in machining. J Mater Process Technol 183:77–87
Lazoglu I, Ulutan D, Alaca BE, Engin S, Kaftanoglu B (2008) An enhanced analytical model for residual stress prediction in machining. CIRP Annals - Manuf Technol 57:81–84
Liang SY, Su JC (2007) Residual stress modeling in orthogonal machining. CIRP Annals—Manuf Technol 56(1):65–68
Ficquet X, Truman CE, Kingston E, Smith DJ (2006) Measurement of residual stresses in aluminium alloy aerospace components. 25th International Congress of the Aeronautical Sciences
Caruso S, Umbrello D, Outeiro JC, Filice L, Micari F (2011) An experimental investigation of residual stresses in hard machining of AISI 52100 steel. Pro Eng 19:67–72
Rossini NS, Dassisti M, Benyounis KY, Olabi AG (2012) Methods of measuring residual stresses in components. Mater Des 35:572–588
Borja C, Virginia GN, Oscar G, Ana A, Carmen S (2011) Influences of turning parameters in surface residual stresses in AISI 4340 steel. Int J Adv Manuf Technol 53:911–919
Jacobus K, DeVor RE, Kapoor SG (2000) Machining-induced residual stress: experimentation and modeling. J Manuf Sci Eng 122(1):20–30
Wei Y, Wang XW (2007) Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts. Int J Adv Manuf Technol 33:260–265
Outeiroa JC, Umbrello D, Saoubi RM (2006) Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel. Int J Mach Tools Manuf 46:1786–1794
Kuang HF, Wu CF (1995) A residual stress model for the milling of aluminum alloy(2014-T6). J Mater Process Technol 51:87–105
Mohammadpour M, Razfar MR, Jalili Saffar R (2010) Numerical investigating the effect of machining parameters on residual stresses in orthogonal cutting. Simul Model Pract Th 18:378–389
Fan N, Chen M, Guo PQ, (2009) Simulation of cutting tool geometry parameters impact on residual stress. 2009 Chinese Control and Decision Conference (CCDC 2009): 5472–5475.
Mohamed NA, Ng EG, Elbestawi MA (2007) Modelling the effects of tool-edge radius on residual stresses when orthogonal cutting AISI 316L. Int J Mach Tools Manuf 47(2):401–411
Tang ZT, Liu ZQ, Pan YZ, Wan Y, Ai X (2009) The influence of tool flank wear on residual stresses induced by milling aluminum alloy. J Mater Process Technol 209(2):4502–4508
Lin ZC, Lai WL, Lin HY, Liu CR (1997) Residual stresses with different tool flank wear lengths in the ultra-precision machining of Ni-P alloys. J Mater Process Technol 65:116–126
Muñoz-Sánchez A, Canteli JA, Cantero JL, Miguélez MH (2011) Numerical analysis of the tool wear effect in the machining induced residual stresses. Simul Model Pract Th 19:872–886
Robinson JS, Tanner DA, Truman CE, Paradowska AM, Wimpory RC (2012) The influence of quench sensitivity on residual stresses in the aluminium alloys 7010 and 7075. Mater Charact 65:73–85
Richter-Trummer V, Suzano E, Beltrão M, Roos A, dos Santos JF, de Castro PMST (2012) Influence of the FSW clamping force on the final distortion and residual stress field. Mater Sci Eng, A 538:81–88
Li BZ, Jiang XH, Jing HJ, Zuo XY (2011) High-speed milling characteristics and the residual stresses control methods analysis of thin-walled parts. Adv Mater Res 223:456–463
Jiang XH, Li BZ, Yang JG, Zuo XY, Li K (2012) An approach for analyzing and controlling residual stress generation during high-speed circular milling. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4421-8, Online First™
Kuruppu MD, Williams JF, Bridgford N, Jones R, Stouffer DC (1992) Constitutive modelling of the elastic–plastic behaviour of 7050-T7451 aluminium alloy. J Strain Anal Eng Des 27:85–92
Third Wave Systems, Inc. (2010) AdvantEdge v5.6-014 machining simulation software. Minneapolis, MN
Hu HJ, Huang WJ (2012) Effects of turning speed on high-speed turning by ultrafine-grained ceramic tool based on 3D finite element method and experiments. Int J Adv Manuf Technol. doi:10.1007/s00170-012-4535-z
Jing S, Liu CR (2004) The influence of material models on finite element simulation of machining. J Manuf Sci Eng 126:849–857
Jiang F, Li JF, Sun J, Zhang S, Wang ZQ, Yan L (2010) Al7050-T7451 turning simulation based on the modified power-law material model. Int J Adv Manuf Technol 48:871–880
Marusich TD, Ortiz M (1995) Modelling and simulation of high-speed machining. J Num Meth Eng 38(21):3675–3694
Marusich TD, Askari E (2001) Modeling residual stress and workpiece quality in machined surfaces. Third Wave Systems Inc, Minneapolis
Coto B, Navas VG, Gonzalo O, Aranzabe A, Sanz C (2011) Influences of turning parameters in surface residual stresses in AISI 4340 steel. Int J Adv Manuf Technol 53:911–919
Eigenmann B, Macherauch E (1996) Roentgenographische untersuchung von spannugszustaenden in werkstoffen (teil 3) Mat-wiss U Werkstoff technik 27: 427–431
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jiang, X., Li, B., Yang, J. et al. Effects of tool diameters on the residual stress and distortion induced by milling of thin-walled part. Int J Adv Manuf Technol 68, 175–186 (2013). https://doi.org/10.1007/s00170-012-4717-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4717-8