Abstract
As the main factor, residual stress undoubtedly restricts the long-term stability of high-precision machining quality parts, arresting an extensive attention on studying its control method. Therefore, a model is meticulously proposed, along with the optimization method of the overlap rate of cutting tool path. In the roughing, the selection of a larger magnitude of overlap coefficient K is found to be necessary for the optimization of the surface machined residual stress, followed by an indispensable selection of smaller K values in the finishing. The shrinking overlap coefficient K echoes with the decreasing influence of the deformation affected by the residual stress distribution, inevitably accompanied by the lowering material removal rate. Based on all the optimization results, an aerospace thin-walled part is adopted in the application case to verify the proposed approach.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Boiten RG, Cate WT (1952) A routine method for the measurement of residual stresses in plates. Appl Sci Res 3(5):317–343
Toshiaki S, Sasahara H, Tsutsumi M (2004) Development of a new tool to generate compressive residual stress within a machined surface. Int J Mach Tools Manuf 44:1215–1221
Arunachalam RM, Mannan MA, Spowage AC (2004) Residual stress and surface roughness when facing age hardened Inconel 718 with CBN and ceramic cutting tools. Int J Mach Tools Manuf 44:879–887
Navas VG, Gonzalo O, Bengoetxea I (2012) Effect of cutting parameters in the surface residual stresses generated by turning in AISI4340 steel. Int J Mach Tools Manuf 61:48–57
Sasahara H, Obikawa T, Shirakashi T (1996) FEM analysis of cutting sequence effect on mechanical characteristics in machined layer. J Mater Process Tech 62:448–453
Liu CR, Guo Y (2000) Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer. Int J Mech Sci 42:1069–1086
Nasr MNA (2015) Effects of sequential cuts on residual stresses when orthogonal cutting steel AISI 1045. Procedia CIRP 31:118–123
Wang ZJ, Chen WJ, Zhang YD, Chen ZT, Liu Q (2005) Study on the machining distortion of thin-walled part caused by redistribution of residual stress. Chin J Aeronaut 18(2):175–179
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
Fergani O, Jiang XH, Shao YM, Welo T, Yang JG, Liang SY (2016) Prediction of residual stress regeneration in multi-pass milling. Int J Adv Manuf Technol 83:1153–1160
Robinson JS, Tanner DA, Truman CE, Wimpory RC (2011) Measurement and prediction of machining induced redistribution of residual stress in the aluminium alloy 7449. Exp Mech 51:981–993
Shao YM, Fergani O, Li BZ, Liang SY (2016) Residual stress modeling in minimum quantity lubrication grinding. Int J Adv Manuf Technol 83:743–751
Zeng HH, Yan R, Peng FY, Zhou L, Deng B (2017) An investigation of residual stresses in micro-end-milling considering sequential cuts effect. Int J Adv Manuf Technol. doi:10.1007/s00170-017-0088-5
Li JG, Wang SQ (2017) Distortion caused by residual stresses in machining aeronautical aluminum alloy parts—recent advances. Int J Adv Manuf Technol 89:997–1012
Treuting RG, Read WT (1951) A mechanical determination of biaxial residual stress in sheet materials. JAppl Phys 22(2):130–134
Sosa AD, Echeverria MD, Moncada OJ, Sikora JA (2007) Residual stresses, distortion and surface roughness produced by grinding thin wall ductile iron plates. Int J Mach Tools Manuf 47:229–235
Omar F, Lazoglu I, Ali M, Mohamed EM, Liang SY (2014) Analytical modeling of residual stress and the induced deflection of a milled thin plate. Int J Adv Manuf Technol 75:455–463
Omar F, Ali M, Lazoglu I, Yang JG, Liang SY (2014) Prediction of residual stress induced distortions in micro-milling of Al7050 thin plate. Appl Mech Mater 472:677–681
Sasahara H (2005) The effect on fatigue life of residual stress and surface hardness resulting from different cutting conditions of 0.45%C steel. Int J Mach Tools Manuf 45:131–136
Li BZ, Jiang XH, Yang JG, Liang SY (2015) Effects of depth of cut on the distortion and redistribution of residual stress during the milling of thin-walled part. J Mater Pro Technol 216:223–233
Jing S, Liu CR (2004) The influence of material models on finite element simulation of machining. J Manuf Sci Eng 126:849–857
Bil H, Kılıc SE, Tekkaya AE (2004) A comparison of orthogonal cutting data from experiments with three different finite element models. Int J Mach Tools Manuf 44:933–944
Third Wave Systems, I. (2010). AdvantEdge v5.6-014 Machining Simulation Software. Inc Minneapolis, MN.
Marusich TD, Ortiz M (1995) Modelling and simulation of high-speed machining. J Num Meth in Eng 38(21):3675–3694
T.D. Marusich, E. Askari. (2001). Modeling residual stress and workpiece quality in machined surfaces. Third Wave Systems, Inc Minneapolis.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jiang, X., Zhang, Z., Ding, Z. et al. Tool overlap effect on redistributed residual stress and shape distortion produced by the machining of thin-walled aluminum parts. Int J Adv Manuf Technol 93, 2227–2242 (2017). https://doi.org/10.1007/s00170-017-0693-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0693-3