Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal
Abstract
:1. Introduction
2. Materials and Methods
2.1. Analytical Formulation
2.2. Experimental Implementation
3. Results
4. Discussion
5. Conclusions
- The effects of the initial deformation and machining stresses (MIRS) must be considered for BIRS characterization due to the big influence in stress values, especially near the surface.
- Using the formulation to perform inversely the calculation of distortion, a check of the results accuracy can be done, as well as a prediction of machining distortion for face milling operations with a negligible computation time.
- The proposed characterization method enables the identification of the BIRS from measured curvatures on machining blanks accurately.
- Parametric sensitivity analysis confirms that accurate assessment of MIRS is necessary to obtain reliable results of bulk residual stresses (BIRS) by the on-machine LR method.
- The effect of the different machining conditions on the final part distortion, and by extension the effect of the MIRS, was verified by the parametric sensitivity analysis.
- The on-machine layer removal method can be implemented in industrial environments by untrained staff using common industrial machines and tools. This fact enables BIRS identification in the shop-floor and allows automation in a future prospect.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Mechanical Properties | Al7050-T7451 |
---|---|
Tensile Yield Strength [MPa] | 469 |
Modulus of Elasticity [GPa] | 71.7 |
Poisson’s ratio [-] | 0.33 |
Density [g/cm3] | 2.83 |
Parameter | Value |
---|---|
Cutting speed—Vc (m·min−1) | 500 |
Feed per tooth—f (mm) | 0.1 |
Axial depth of cut—ap (mm) | 1 |
Radial depth of cut—ae (mm) | 30 |
Parameter | Exp. | Bib. No. 1 | Bib. No. 2 | Bib. No. 3 |
---|---|---|---|---|
Tool Diameter | 40 | 32 | 32 | 32 |
Cutting speed—Vc (m·min−1) | 500 | 200 | 800 | 1400 |
Feed per tooth—f (mm) | 0.1 | 0.2 | 0.2 | 0.2 |
Axial depth of cut—ap (mm) | 1 | 1 | 1 | 1 |
Radial engagement—(%) | 75 | 75 | 75 | 75 |
Rake angle—(°) | 20 | 11 | 11 | 11 |
Clearance angle—(°) | 15 | 8 | 8 | 8 |
Corner radius—(mm) | 0.4 | 0.2 | 0.2 | 0.2 |
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Aurrekoetxea, M.; López de Lacalle, L.N.; Llanos, I. Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal. Materials 2020, 13, 1445. https://doi.org/10.3390/ma13061445
Aurrekoetxea M, López de Lacalle LN, Llanos I. Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal. Materials. 2020; 13(6):1445. https://doi.org/10.3390/ma13061445
Chicago/Turabian StyleAurrekoetxea, Maria, Luis Norberto López de Lacalle, and Iñigo Llanos. 2020. "Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal" Materials 13, no. 6: 1445. https://doi.org/10.3390/ma13061445