Methodology for prediction of distortion of workpieces manufactured by high speed machining based on an accurate through-the-thickness residual stress determination

• Type: Article in International Scientific Journal
• Date: 2013

Authors

Paulo Tavares de Castro (Author) FEUP; V. Richter-Trummer (Author) FEUP; D. Koch (Author) Other; A. Witte (Author) Other; J.F. dos Santos (Author) Other

Journal

Title: International Journal of Advanced Manufacturing Technology

Vol. 68

Pages: 2271-2281

ISSN: 0268-3768

Publisher: Springer Nature

Indexing

ISI Web of Knowledge - 26 Citations

Scopus - 39 Citations

Other information

Authenticus ID: P-006-6VF

DOI: 10.1007/s00170-013-4828-x

Abstract (EN): After high-speed machining of rolled and stretch straightened aluminium sheets, out-of-plane distortion is found. This is especially true for complex machined shapes in thin-gauge and high-strength aluminium alloys. This kind of sheets are mostly found in the aeronautical industry, where thin-weight-optimised aluminium shell designs are used for skin applications. Usually, in the aeronautical sector, low-thickness sections are used wherever possible, and higher thicknesses are used only where additional strength is required. In the present work, a methodology of predicting workpiece distortion based on the residual stress present in the workpiece is presented, which can be applied by machining companies without further investment in measurement equipment. A method for accurately determining through-the-thickness residual stresses was adapted to the special requirements of this industrial sector. The measured residual stresses were used in a finite element model capable of approximately calculating the shape distortion of simple and complex high-speed machined parts. Promising results have been obtained.

Language: English

Type (Professor's evaluation): Scientific

No. of pages: 11