Skip to main content
SpringerLink
Log in

Investigation on the influence of the equivalent bending stiffness of the thin-walled parts on the machining deformation

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A semi-analytical model considering the biaxial blank residual stress is proposed to predict the machining deformation of the thin-walled parts. Machining deformations of five thin-walled parts with different stiffening rib layouts are calculated using the proposed model, and the accuracy of the model is validated by FEM simulations and machining experiments. In comparison with the experimental results, the relative errors of the final vertex deformations calculated by the proposed model for specimens 1–5 are 3.08%, 5.66%, 9.15%, 3.60%, and 8.43%, respectively. Then, the influence of the equivalent bending stiffness on the machining deformation is investigated. Results show that, compared with specimen 1, the equivalent bending stiffness in the X direction of specimens 2–5 are increased by 35.48%, 94.02%, 96.29%, and 100.15%, respectively; meanwhile, the maximum deformations are decreased by 23.42%, 30.92%, 30.66%, and 17.72%, respectively. The machining deformation decreases with the increase of equivalent bending stiffness in the length direction, and the equivalent stiffness in the width direction has no significant influence on the overall machining deformation. Stiffening ribs can be added to increase the bending stiffness and decrease the deformation in machining process. The deformation can be further reduced when the stiffening ribs are placed closer to the maximum deformation point.

Graphical abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Fielder R, Montoya A, Millwater H, Golden P (2017) Residual stress sensitivity analysis using a complex variable finite element method. Int J Mech Sci 133:112–120. https://doi.org/10.1016/j.ijmecsci.2017.08.035

    Article  Google Scholar 

  2. Gao HJ, Zhang YD, Wu Q, Song J (2017) Experimental investigation on the fatigue life of Ti-6Al-4V treated by vibratory stress relief. Metals (Basel) 7:158. https://doi.org/10.3390/met7050158

    Article  Google Scholar 

  3. Gao H, Zhang Y, Wu Q, Song J, Wen K (2018) Fatigue life of 7075-T651 aluminium alloy treated with vibratory stress relief. Int J Fatigue 108:62–67. https://doi.org/10.1016/j.ijfatigue.2017.11.011

    Article  Google Scholar 

  4. Li Y, Zhou K, Tan P, Tor SB, Chua CK, Leong KF (2018) Modeling temperature and residual stress fields in selective laser melting. Int J Mech Sci 136:24–35. https://doi.org/10.1016/j.ijmecsci.2017.12.001

    Article  Google Scholar 

  5. Wang F, Mao K, Li B (2018) Prediction of residual stress fields from surface stress measurements. Int J Mech Sci 140:68–82. https://doi.org/10.1016/j.ijmecsci.2018.02.043

    Article  Google Scholar 

  6. Huang X, Sun J, Li J (2015) Finite element simulation and experimental investigation on the residual stress-related monolithic component deformation. Int J Adv Manuf Technol 77:1035–1041. https://doi.org/10.1007/s00170-014-6533-9

    Article  Google Scholar 

  7. Wang J, Zhang D, Wu B, Luo M (2018) Prediction of distortion induced by machining residual stresses in thin-walled components. Int J Adv Manuf Technol 95(1–10):4153–4162. https://doi.org/10.1007/s00170-017-1358-y

    Article  Google Scholar 

  8. Liu L, Sun J, Chen W, Sun P (2015) Study on the machining distortion of aluminum alloy parts induced by forging residual stresses. Proc Inst Mech Eng Part B J Eng Manuf 231:1–10. https://doi.org/10.1177/0954405415583805

    Google Scholar 

  9. Jiang Z, Liu Y, Li L, Shao W (2014) A novel prediction model for thin plate deflections considering milling residual stresses. Int J Adv Manuf Technol 74:37–45. https://doi.org/10.1007/s00170-014-5952-y

    Article  Google Scholar 

  10. D’Alvise L, Chantzis D, Schoinochoritis B, Salonitis K (2015) Modelling of part distortion due to residual stresses relaxation: an aeronautical case study. Procedia CIRP 31:447–452. https://doi.org/10.1016/j.procir.2015.03.069

    Article  Google Scholar 

  11. Huang K, Yang W, Ye X (2018) Adjustment of machining-induced residual stress based on parameter inversion. Int J Mech Sci 135:43–52. https://doi.org/10.1016/j.ijmecsci.2017.11.014

    Article  Google Scholar 

  12. Huang K, Yang W (2016) Analytical modeling of residual stress formation in workpiece material due to cutting. Int J Mech Sci 114:21–34. https://doi.org/10.1016/j.ijmecsci.2016.04.018

    Article  Google Scholar 

  13. Huang K, Yang W (2016) Analytical model of temperature field in workpiece machined surface layer in orthogonal cutting. J Mater Process Technol 229:375–389. https://doi.org/10.1016/j.jmatprotec.2015.07.008

    Article  Google Scholar 

  14. Huang K, Yang W, Chen Q (2015) Analytical model of stress field in workpiece machined surface layer in orthogonal cutting. Int J Mech Sci 103:127–140. https://doi.org/10.1016/j.ijmecsci.2015.08.020

    Article  Google Scholar 

  15. Huang K, Yang W (2017) Analytical analysis of the mechanism of effects of machining parameter and tool parameter on residual stress based on multivariable decoupling method. Int J Mech Sci 128–129:659–679. https://doi.org/10.1016/j.ijmecsci.2017.05.031

    Article  Google Scholar 

  16. Yang D, Liu Z (2015) Surface plastic deformation and surface topography prediction in peripheral milling with variable pitch end mill. Int J Mach Tools Manuf 91:43–53. https://doi.org/10.1016/j.ijmachtools.2014.11.009

    Article  Google Scholar 

  17. Cheng Y, Zuo D, Wu M, Feng X, Zhang Y (2015) Study on simulation of machining deformation and experiments for thin-walled parts of titanium alloy. Int J Control Autom 8:401–410. https://doi.org/10.14257/ijca.2015.8.1.38

    Article  Google Scholar 

  18. Diez E, Perez H, Marquez J, Vizan A (2015) Feasibility study of in-process compensation of deformations in flexible milling. Int J Mach Tools Manuf 94:1–14. https://doi.org/10.1016/j.ijmachtools.2015.03.008

    Article  Google Scholar 

  19. Ma Y, Feng P, Zhang J, Wu Z, Yu D (2016) Prediction of surface residual stress after end milling based on cutting force and temperature. J Mater Process Technol 235:41–48. https://doi.org/10.1016/j.jmatprotec.2016.04.002

    Article  Google Scholar 

  20. Cerutti X, Mocellin K (2015) Parallel finite element tool to predict distortion induced by initial residual stresses during machining of aeronautical parts. Int J Mater Form 8:255–268. https://doi.org/10.1007/s12289-014-1164-0

    Article  Google Scholar 

  21. Pugazhenthi A, Kanagarajc G, Dinaharand I, David Raja Selvame J (2018) Turning characteristics of in situ formed TiB2 ceramic particulate reinforced AA7075 aluminum matrix composites using polycrystalline diamond cutting tool. MEASUREMENT 121:39–46. https://doi.org/10.1016/j.measurement.2018.02.039

    Article  Google Scholar 

  22. Nieslony P, Krolczyk GM, Wojciechowski S, Chudy R, Zak K, Maruda RW (2018) Surface quality and topographic inspection of variable compliance part after precise turning. Appl Surf Sci 434:91–101. https://doi.org/10.1016/j.apsusc.2017.10.158

    Article  Google Scholar 

  23. Li JG, Wang SQ (2017) Distortion caused by residual stresses in machining aeronautical aluminum alloy parts: recent advances. Int J Adv Manuf Technol 89:997–1012. https://doi.org/10.1007/s00170-016-9066-6

    Article  Google Scholar 

  24. Li B, Jiang X, Yang J, Liang SY (2015) Effects of depth of cut on the redistribution of residual stress and distortion during the milling of thin-walled part. J Mater Process Technol 216:223–233. https://doi.org/10.1016/j.jmatprotec.2014.09.016

    Article  Google Scholar 

  25. Zhang Z, Li L, Yang Y, He N, Zhao W (2014) Machining distortion minimization for the manufacturing of aeronautical structure. Int J Adv Manuf Technol 73:1765–1773. https://doi.org/10.1007/s00170-014-5994-1

    Article  Google Scholar 

  26. Cerutti X, Mocellin K, Hassini S, Blaysat B, Duc E (2017) Methodology for aluminium part machining quality improvement considering mechanical properties and process conditions. CIRP J Manuf Sci Technol 18:18–38. https://doi.org/10.1016/j.cirpj.2016.07.004

    Article  Google Scholar 

  27. Wojciechowski S, Maruda RW, Barrans S, Nieslony P, Krolczyk GM (2017) Optimisation of machining parameters during ball end milling of hardened steel with various surface inclinations. MEASUREMENT 111:18–28. https://doi.org/10.1016/j.measurement.2017.07.020

    Article  Google Scholar 

  28. Wu Q, Li DP, Zhang YD (2016) Detecting milling deformation in 7075 aluminum alloy aeronautical monolithic components using the quasi-symmetric machining method. Metals (Basel) 6:80. https://doi.org/10.3390/met6040080

    Article  Google Scholar 

  29. Masoudi S, Amini S, Saeidi E, Eslami-Chalander H (2014) Effect of machining-induced residual stress on the distortion of thin-walled parts. Int J Adv Manuf Technol 76:597–608. https://doi.org/10.1007/s00170-014-6281-x

    Article  Google Scholar 

  30. Yang Y, Li M, Li KR (2014) Comparison and analysis of main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component. Int J Adv Manuf Technol 70:1803–1811. https://doi.org/10.1007/s00170-013-5431-x

    Article  Google Scholar 

  31. Rafey Khan A, Nisar S, Shah A, Khan MA, Khan SZ, Sheikh MA (2017) Reducing machining distortion in AA 6061 alloy through re-heating technique. Mater Sci Technol (United Kingdom) 33:731–737. https://doi.org/10.1080/02670836.2016.1243335

    Article  Google Scholar 

  32. Husson R, Baudouin C, Bigot R, Sura E (2014) Consideration of residual stress and geometry during heat treatment to decrease shaft bending. Int J Adv Manuf Technol 72:1455–1463. https://doi.org/10.1007/s00170-014-5688-8

    Article  Google Scholar 

  33. Gao H, Zhang Y, Wu Q, Song J (2017) An analytical model for predicting the machining deformation of a plate blank considers biaxial initial residual stresses. Int J Adv Manuf Technol 93(1–4):1473–1486. https://doi.org/10.1007/s00170-017-0528-2

    Article  Google Scholar 

  34. Timoshenko S, Woinosky-Krieger S (1959) Theory of plates and shells classic. McGraw-Hill, New York, USA

    Google Scholar 

  35. Gere JM, Goodno BJ (1972) Mechanics of materials. In: Mechanics of materials, vol 41. Van Nostrand Reinhold Co., New York, NY, USA, pp 211–291. https://doi.org/10.1016/j.mechmat.2009.01.011

    Google Scholar 

  36. Xv Q (2016) Idea and method for solving elastic problem of rectangular boundary. Tsinghua university press, Beijing, China (In Chinese)

    Google Scholar 

  37. Greving DJ, Rybicki EF, Shadley JR (1994) Through-thickness residual stress evaluations for several industrial thermal spray coatings using a modified layer-removal method. J Therm Spray Technol 3(4):379–388

    Article  Google Scholar 

Download references

Acknowledgements

This work is financially supported by the China National Natural Science Foundation (No. 5177041109).

Author information

Author notes

  1. Hongbin Deng

    Present address: School of Mechatronical Engineering, Beijing Institute of Technology, Beijing City, 5 Zhongguan Cun South Street, HaiDian District, Beijing, 100081, People’s Republic of China

Authors and Affiliations

  1. School of Mechatronical Engineering, Beijing Institute of Technology, Beijing City, 5 Zhongguan Cun South Street, HaiDian District, Beijing, 100081, People’s Republic of China

    Bianhong Li

  2. Institute of Orthopaedics and Musculoskeletal Science, Division of Surgery and Interventional Science, The Royal National Orthopaedic Hospital, University College London, Stanmore, London, HA7 4LP, UK

    Bianhong Li & Hanjun Gao

  3. State Key Laboratory of Virtual Reality Technology and Systems, School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, People’s Republic of China

    Hanjun Gao

  4. China Weaponry Huaihai Industrial Group, Changzhi City, Shanxi Province, 046000, People’s Republic of China

    Hai Pan & Baoguo Wang

Authors
  1. Bianhong Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hanjun Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hongbin Deng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hai Pan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Baoguo Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hongbin Deng.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Highlights

• A semi-analytical machining deformation prediction model of the thin-walled parts is proposed.

• Machining deformations of five study cases are predicted by the proposed model, and corresponding experiments and FEM simulations are conducted to validate the proposed model.

• The influences of the equivalent bending stiffness on the machining deformation are investigated based on the proposed model.

• The results show that the machining deformation decreases with the increase of equivalent bending stiffness in the length direction. Stiffening ribs can be added to increase the bending stiffness and decrease the deformation in machining process.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, B., Gao, H., Deng, H. et al. Investigation on the influence of the equivalent bending stiffness of the thin-walled parts on the machining deformation. Int J Adv Manuf Technol 101, 1171–1182 (2019). https://doi.org/10.1007/s00170-018-2987-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2987-5

Keywords

Search

Navigation