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Research on surface residual stresses generated by milling Ti6Al4V alloy under different pre-stresses

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Abstract

Machining-induced residual stress plays a significant role in the corrosion resistance and fatigue life of the manufacturing end product. In the current study, milling experiments were performed to investigate the influence of pre-stress on the surface residual stresses. For this purpose, finite element (FE) simulations of the orthogonal cutting based on arbitrary Lagrangian-Eulerian approach were performed. To validate the simulation results, a device was designed to stretch the workpiece with pre-stresses before the machining process. The residual stresses obtained under different pre-stresses were measured based on the varied bending deflection of the workpiece after each material layer removal. As a result, the general variation trend of residual stress profiles that obtained under different pre-stresses was found well consistent with the finite element simulation results, indicating that the proposed residual stress measuring principle is reliable. Furthermore, the pre-stress loaded on the Ti6Al4V part can significantly affect the distribution of machining-induced residual stresses, implying that surface residual stresses can be adjusted by employing appropriate values of pre-stresses during the machining process.

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Funding

The authors are extremely thankful for the support of the Natural Science Foundation of Jiangsu Province (BK20190676) and the Natural Science Research of Jiangsu Higher Education Institutions of China (19KJB460019). In addition, authors also express their gratitude to the National Natural Science Foundation of China (51635003) and the Special Fund of Jiangsu Province for Transformation of Scientific and Technological Achievements (BA2017099) for their assistance and funding.

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Nanjing Tech University, Nanjing, 211816, People’s Republic of China

    Longhui Meng, Hao Zhang & Chenggang Fang

  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Aqib Mashood Khan & Ning He

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  1. Longhui Meng
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  2. Aqib Mashood Khan
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  3. Hao Zhang
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  4. Chenggang Fang
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Correspondence to Longhui Meng or Aqib Mashood Khan.

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Meng, L., Khan, A.M., Zhang, H. et al. Research on surface residual stresses generated by milling Ti6Al4V alloy under different pre-stresses. Int J Adv Manuf Technol 107, 2597–2608 (2020). https://doi.org/10.1007/s00170-020-05165-5

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