Numerical and experimental investigations of post-machining distortions in thin machined structures considering material-induced residual stress
详细信息 查看全文
- 作者：W. Saleem Awan ; Tarek Mabrouki
- 关键词：Machining distortions ; Residual stress ; Cutting simulations ; FEA
- 刊名：Journal of the Brazilian Society of Mechanical Sciences and Engineering
- 出版年：2017
- 出版时间：February 2017
- 年：2017
- 卷：39
- 期：2
- 页码：509-521
- 全文大小：
- 刊物主题：Mechanical Engineering;
- 出版者：Springer Berlin Heidelberg
- ISSN：1806-3691
- 卷排序：39
文摘
Post-machining part distortions are commonly observed in thin-walled machined structures. This problem is intensified if the machined part is cellular, curved in profile, and complex in design. Different customized techniques are executed to overcome this issue and to attain the desired dimensional accuracy. This problem instigates mainly due to redistribution of material-induced residual stress subsequent to machining operations. Research work presented here deals with numerical and experimental investigations of part distortions encountered in thin-walled machined structures. Computational analysis and manufacturing simulations of cutting operations are executed in ANSYS® software. Computational work is validated through actual experimentation on a computerized numerical controlled machine with optimum cutting parameters. Coordinate measuring machine (CMM) geometric inspection is carried out to determine the attained machining accuracy. Material-induced residual stress is developed through sequential coupled field thermo-mechanical analysis. Large-scale cutting simulations are performed in an optimized sequence by employing element birth–death feature. Simulation predicted distortions and CMM statistics is evaluated, and it was found that both corroborate with each other. This validates the approach adopted to predict part distortions.