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Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Irene Del Sol, Asuncion Rivero, Luis Norberto López de Lacalle, Antonio Juan Gamez
2019 Materials  
This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through  ...  Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections.  ...  Conflicts of Interest: The authors declare no conflict of interest.  ... 
doi:10.3390/ma12122012 pmid:31234596 pmcid:PMC6630719 fatcat:jd4utuco7fdvrpzduqsaqtxbpu

Residual stress relaxation considering microstructure evolution in heat treatment of metallic thin-walled part

Qian Bai, Ziliang Chen, Yingming Gao, Hang Li, Jingang Tang
2022 High Temperature Materials and Processes  
The forming-induced residual stress of metallic parts could cause undesired deformation in the final machining process, especially for the thin-walled parts.  ...  This study could provide guidance to the elimination of the residual stress and the improvement of the geometrical accuracy for thin-walled parts in the machining process.  ...  Acknowledgment: The financial supports from the Science Challenge Project (JCKY2016212A506-0101) and the National Natural Science Foundation of China (52175381) are gratefully acknowledged.  ... 
doi:10.1515/htmp-2022-0036 fatcat:opg34y2lmnea5kkg4qjpkh35be

Machining Surface Quality Analysis of Aluminum Alloy Thin-Walled Parts in Aerospace

Dai Bing, Yu Guang-bin, Guan Yan-qi, Shao Jun-peng, Wu Xue-mei, Liu Yu-xin
2015 International Journal of Security and Its Applications  
It is of great significance to improve the machining efficiency of the aluminum alloy thin-walled parts, and a series of analysis of the surface quality of aluminum alloy thin-walled parts there are carried  ...  There are many key parts in the field of aerospace with aluminum alloy thin-walled parts, the problem of breaking the low efficiency in production that's also followed.  ...  Acknowledgements The research in this paper is supported by the Ministry of science and technology international cooperation project (2014DFA72990).  ... 
doi:10.14257/ijsia.2015.9.11.19 fatcat:fcnhouuhbfe55bhv7evxthhsbm

Effect of Vibration Stress Relief on the Shape Stability of Aluminum Alloy 7075 Thin-Walled Parts

Hai Gong, Yanjie Sun, Yaoqiong Liu, Yunxin Wu, Yipeng He, Xiaoliang Sun, Minghai Zhang
2018 Metals  
It was concluded that VSR improved the shape and size stability of the material to a significant level by relieving induced residual stresses in the thin-walled parts.  ...  In this work, an experimental study of the effect of VSR (Vibratory Stress Relief) on the deformation and residual stresses of aluminum alloy 7075 thin-walled components is presented.  ...  Conflicts of Interest: The authors declare no conflict of interest.  ... 
doi:10.3390/met9010027 fatcat:bivjx6wi5rdllcali62q4bg724

Virtual Minimization of Residual Stress and Deflection Error in Five-Axis Milling of Turbine Blades

Mohsen Soori, Mohammed Asmael
2021 figshare.com  
To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained.  ...  In the present research work, application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in 5-axis milling operations of turbine blades.  ...  DEFLECTION ERROR ANALYSIS OF THIN-WALL WORKPIECE IN MACHINING OPERATIONS The machining operations of thin-walled parts are with deflection error as a result of cutting forces as well as cutting temperature  ... 
doi:10.6084/m9.figshare.14561577.v1 fatcat:s5a42zcefrhp5k4vombb7cswbm

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Mohsen Soori, Mohammed Asmael
2021 Strojniski vestnik  
To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained.  ...  In the present research work, the application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades  ...  [15] to decrease the residual stress in machined parts. A variable depth-of-cut milling strategy for thin-walled workpiece is proposed by Yan et al.  ... 
doi:10.5545/sv-jme.2021.7113 fatcat:72dqm26kfre6vom5swkosgjwv4

Virtual Minimization of Residual Stress and Deflection Error in Five-Axis Milling of Turbine Blades

Mohsen Soori, Mohammed Asmael
2021 figshare.com  
To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained.  ...  In the present research work, application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in 5-axis milling operations of turbine blades.  ...  [15] to decrease the residual stress in machined parts. A variable depth-of-cut milling strategy for thin-walled workpiece is proposed by Yan et al.  ... 
doi:10.6084/m9.figshare.14561577.v2 fatcat:a44663poordlpdb6tbtpugscia

Effect of Initial Residual Stress and Machining-Induced Residual Stress on the Deformation of Aluminium Alloy Plate

Xiaoming Huang, Jie Sun, Jianfeng Li
2015 Strojniski vestnik  
During the machining of aerospace thin-walled components, a large amount material is removed, and machining-induced residual stress is induced in the boundary layer of the work piece, which results in  ...  The coupling action of compressive initial residual stress and machining-induced residual stress increase the plate deformation, and the coupling action of tensile initial residual stress and machining-induced  ...  ACKNOWLEDGEMENTS The authors want to thank for the support from the National Natural Science Foundation of China (No. 51275277).  ... 
doi:10.5545/sv-jme.2014.1897 fatcat:mdoysfl64zddhdum35q7ccnj6q

Advances in additive manufacturing process simulation: Residual stresses and distortion predictions in complex metallic components

Xu Song, Stefanie Feih, Wei Zhai, Chen-Nan Sun, Feng Li, Raj Maiti, Jun Wei, Yangzhan Yang, Victor Oancea, Leon Romano Brandt, Alexander M. Korsunsky
2020 Materials & design  
For the LDED processes, thin wall components are simulated, and residual stresses predictions are compared with both FIB-DIC and XRD measurement results at different scales.  ...  position and time to achieve process simulation of complex 3D parts.  ...  Declaration of competing interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper  ... 
doi:10.1016/j.matdes.2020.108779 fatcat:cxl33vjqufadrnurkeazi5i4gi

Finite Element Analysis of the Milling of Ti6Al4V Titanium Alloy Laser Additive Manufacturing Parts

Zhaohui Ren, Xingwen Zhang, Yunhe Wang, Zhuhong Li, Zhen Liu
2021 Applied Sciences  
This study aimed to analyze the defects of large residual stress in laser additive manufacturing metal parts by establishing a milling numerical simulation of Ti6Al4V titanium alloy thin-walled parts based  ...  The influences of milling depth, initial temperature and milling speed on the forming quality of the formed part were analyzed.  ...  ., studied the effect of milling on the thin-walled parts produced by welding wire arc additive manufacturing.  ... 
doi:10.3390/app11114813 fatcat:nn3jjetkdjdw3kbss752qudp6a

Deformation Prediction and Experimental Study of 316L Stainless Steel Thin-Walled Parts Processed by Additive-Subtractive Hybrid Manufacturing

Xuefeng Wu, Wenbo Zhu, Yu He
2021 Materials  
the changes of stress and deformation of these thin-walled parts after subsequent milling.  ...  (ASHM) of 316L stainless steel thin-walled parts, so as to effectively improve the forming quality of thin-walled parts manufactured by the combined processing of ASHM.  ...  The thermal stress distribution is related to the path of the laser heat source, and thermal stress presents gradient distribution in thin-walled parts.  ... 
doi:10.3390/ma14195582 pmid:34639980 fatcat:vlpwcbircnadrlqesluievumne

Micro-scale finishing of the surface and form of a Ti-6Al-4V lightweight rotor obtained by laser powder bed fusion used for air bearing

Claude Sanz, Romain Gerard, Paul Morantz, Ahmed Chérif, Paul Shore, Hélène Mainaud-Durand, Alexander J.G. Lunt
2018 Additive Manufacturing  
The results demonstrate that despite being able to initially machine the part to a form tolerance approaching 2 μm, subsequent notch cutting and the release of residual stresses from the part obtained  ...  This demonstrates that further minimisation and understanding of the residual stresses induced during machining are required to facilitate the effective manufacture of high precision components of this  ...  Particularly, François Morel for the design of the parts and the metrology group for their accurate measurements.  ... 
doi:10.1016/j.addma.2018.05.033 fatcat:qlty2ba7h5gafa6iglzusdbjma

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

Caixu Yue, Haining Gao, Xianli Liu, Steven Liang
2018 Applied Sciences  
The different cutting conditions will directly affect the surface state of the machined parts (surface texture, surface morphology, surface residual stress, etc.) and affect the final performance of the  ...  At the same time, the relationship between the machined surface integrity and the performance of parts is also revealed.  ...  Conflicts of Interest: The authors declare no conflicts of interest.  ... 
doi:10.3390/app8122550 fatcat:fzsjwbpbibaivpkoqiyejvhuoq

Intelligent Fixtures for High Performance Machining

Hans-Christian Möhring, Petra Wiederkehr
2016 Procedia CIRP  
The second example is related to the compensation of workpiece distortions which occur in machining of large thin walled structural parts.  ...  Fixtures are an essential element of the machining system, being part of the precision path and force flux between process and machine tool.  ...  Deformations of thin-walled workpieces result from gravitational and clamping forces, process loads and residual stresses which appear due to the machining process.  ... 
doi:10.1016/j.procir.2016.04.042 fatcat:m5genyryenh2nmqwjwsecs6wdy

Improving the shape quality of bearing rings in soft turning by using a Fast Tool Servo

Björn L. T. Beekhuis, Ekkard Brinksmeier, Martin Garbrecht, Jens Sölter
2009 Production Engineering  
Moreover, the machining process generates locally varying residual stresses which contribute to shape deviation of the workpiece.  ...  Based on the results, the influence of the cutting forces on part accuracy is discussed.  ...  Acknowledgments The authors would like to thank the Deutsche Forschungsgemeinschaft (DFG) for the financial support of this work within the SFB 570 ''Distortion Engineering''.  ... 
doi:10.1007/s11740-009-0175-z fatcat:spckzy5bijgjhbr5ycovui3kqi
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